Filter mask

ABSTRACT

A filter mask for biological material has a mask body and a strap wherein the strap has a first portion and a second portion that are rigid.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application:

-   -   (a) is a continuation-in part of U.S. patent application Ser.        No. 16/932,118 filed on Jul. 17, 2020:        -   a. which is continuation-in part of each of Ser. No.            16/913,849 filed on Jun. 26, 2020, Ser. No. 16/913,885 filed            on Jun. 26, 2020 and Ser. No. 16/913,919 filed on Jun. 26,            2020, each of which claims the benefit of the filing date of            States Provisional Patent Application No. 62/987,067 filed            on Mar. 9, 2020; U.S. Provisional Patent Application No.            62/993,480 filed on Mar. 23, 2020; U.S. Provisional Patent            Application No. 63/004,803, filed on Apr. 3, 2020; U.S.            Provisional Patent Application No. 63/010,468, filed on Apr.            15, 2020; and U.S. Provisional Patent Application No.            63/027,237, filed on May 19, 2020; entitled FILTER MASK;            and,        -   b. which claims the benefit of the filing date of States            Provisional Patent Application No. 62/987,067 filed on Mar.            9, 2020; U.S. Provisional Patent Application No. 62/993,480            filed on Mar. 23, 2020; U.S. Provisional Patent Application            No. 63/004,803, filed on Apr. 3, 2020; U.S. Provisional            Patent Application No. 63/010,468, filed on Apr. 15, 2020;            and U.S. Provisional Patent Application No. 63/027,237,            filed on May 19, 2020; entitled FILTER MASK; and,    -   (b) claims the benefit of the filing date of States Provisional        Patent Application No. 62/987,067 filed on Mar. 9, 2020; U.S.        Provisional Patent Application No. 62/993,480 filed on Mar. 23,        2020; U.S. Provisional Patent Application No. 63/004,803, filed        on Apr. 3, 2020; U.S. Provisional Patent Application No.        63/010,468, filed on Apr. 15, 2020; and U.S. Provisional Patent        Application No. 63/027,237, filed on May 19, 2020; entitled        FILTER MASK, the contents of each of which are incorporated        herein by reference.

FIELD

This disclosure relates generally to a filter mask (which may bereferred to as a filter mask) such as a mask which may be used to filterbiological contaminants from the air, such as a virus.

INTRODUCTION

The following is not an admission that anything discussed below is partof the prior art or part of the common general knowledge of a personskilled in the art.

Various types of filter masks are known. Typically, a filter mask uses afilter media that overlies the mouth and nose of a person. For example,a surgical mask or an N-95 mask may overlie the nose and mouth of aperson and may be secured by tie members that wrap around a person'sears or the back of a person's head.

SUMMARY

The following introduction is provided to introduce the reader to themore detailed discussion to follow. The introduction is not intended tolimit or define any claimed or as yet unclaimed invention. One or moreinventions may reside in any combination or sub-combination of theelements or process steps disclosed in any part of this documentincluding its claims and figures.

In one aspect of the filter mask disclosed herein, which may be used byitself or with one or more other aspects disclosed herein, there isprovided a mask having a mask body and a first strap for extendingaround a head of a user. The first strap has first and second sideportions that are rigid. An advantage of this design is that the rigidfirst and second side portions may reduce pressure on the head of theuser when the mask is worn. The first and second side portions may bepositioned and adjusted by each user to improve the comfort of the userwhen the mask is worn.

In accordance with this broad aspect, there is provided a maskcomprising:

a mask body having a front and first and second laterally opposed sides,each laterally opposed side having a strap attachment member; and,a first strap for extending around a head of a user, the first strapcomprising a first side portion which, when worn by the user, extendsover a portion of a first lateral side of the head of the user and asecond side portion which, when worn by the user, extends over a portionof a second lateral side of the head of the user, wherein the first sideportion and the second side portion are rigid.

In any embodiment, the first side portion and the second side portionmay be convex.

In any embodiment, when the user is wearing glasses, the first sideportion and the second side portion may be positioned laterallyoutwardly of temples of the glasses.

In any embodiment, each of the first side portion and the second sideportion may engage the head of the user rearward of the temples of theglasses.

In any embodiment, each of the first side portion and the second sideportion may engage the head of the user rearward of the externalacoustic meatus of the head.

In any embodiment, the first side portion and the second side portionmay be made from a rigid plastic.

In any embodiment, the rigid plastic may be ABS, HDPE, nylon orpolycarbonate.

In any embodiment, each of the first side portion and the second sideportion may have a mask body engagement end and a rearwardly disposedopposed end and the first strap may further comprise an adjustable bandwhich may extend between the opposed ends of the first side portion andthe second side portion.

In any embodiment, the adjustable band may comprise an elastomericmaterial.

In any embodiment, the adjustable band may have an adjustable length.

In any embodiment, each of the first side portion and the second sideportion may have a mask body engagement end and a rearwardly disposedopposed end and the mask body engagement ends may be rotatably mountedto the strap attachment members.

In any embodiment, each of the mask body engagement ends may beremovably rotatably mounted to the strap attachment members.

In any embodiment, each of the mask body engagement ends may comprise ahook and each of the strap attachment members may comprise a hookreceiving portion whereby each hook receiving portion may receive one ofthe mask body engagement ends.

In any embodiment, each of the mask body engagement ends may comprise apivot pin receiving portion and each of the strap attachment members maycomprise a pivot pin.

In any embodiment, the mask may further comprise a second strap.

In any embodiment, the second strap may comprise a first side portionwhich, when worn by the user, may extend over a portion of the firstlateral side of the head of the user and a second side portion which,when worn by the user, may extend over a portion of the second lateralside of the head of the user, wherein the first side portion and thesecond side portion of the second strap may be rigid.

In any embodiment, each of the first side portion and the second sideportion may be transparent.

In any embodiment, each of the first side portion and the second sideportion of each of the first strap and the second strap may betransparent.

In accordance with another aspect of this design, which may be used byitself or with one or more aspects disclosed herein, a filter mask usesone or more air treatment members that are positioned above or below aperson's head. An advantage of this design is that the filter does notblock the person's face. Accordingly, a medical worker, such as adoctor, may examine a patient while the patient is wearing the mask andbe able to view all or substantially all of the patient's face through atransparent face plate. Similarly, if a medical worker, such as adoctor, is wearing the mask while examining the patient, the patientwill be able to view all or substantially all of the medical worker'sface. For example, the mask may comprise a transparent face plate thatoverlies at least the mouth and nose of a patient thereby rendering mostor all of the patient's or medical worker's face visible.

Optionally, the face plate overlies the person's mouth, nose and eyesand accordingly may overlie all of the person's face. The face plate maybe part of the mask body (e.g., a single integrally formed face platemay overlie the person's mouth, nose and eyes and form a closed volumebetween the face of a user and the inside of the mask). Alternately, aseparate face shield that overlies the upper face of a user so as tooverlie the eyes of a user, may be mountable, and optionally removablymountable, to the filter mask. An advantage of this embodiment is thatthe person's eyes are covered by the mask and may not be exposed toambient air that may contain a biological contaminant. A furtheradvantage is that a doctor may view all of a patient's face, which mayimprove the diagnosis of a person wearing the mask.

In accordance with another aspect of this design, which may be used byitself or with one or more other aspects disclosed herein, the mask bodymay include a sealing member provided on a user side of the mask body.The sealing member abuts the face of the user to form a closed volumearound the mouth and nose of the user. At least a portion of the sealingmember extends into the closed volume. An advantage of this design isthat the sealing member may conform to each individual user's face toprovide an improved seal against the user's face. In other words, theposition of the seal along the sealing member may vary to improve theseal for each user.

In accordance with this aspect, there is provided a filter maskcomprising:

-   -   a) a mask body having a user side that faces towards a face of        the user when the filter mask is worn by a user; and,    -   b) a sealing member provided on the user side of the mask body,        wherein, when the filter mask is worn by a user, the sealing        member abuts the face of the user whereby a closed volume that        covers the mouth and nose of the user is provided, the closed        volume having a perimeter wherein a portion of the sealing        member extends inwardly of the perimeter into the closed volume.

In any embodiment, the sealing member may comprise a resilient member.

In any embodiment, the sealing member may comprise an open cell foam ora closed cell foam.

In any embodiment, the sealing member may comprise a closed cell foamhaving a stiffness of 10-80 on shore 00 scale.

In any embodiment, the sealing member may have a user side that abutsthe face of the user when the user is wearing the filter mask, the userside of the sealing member may have an inner edge located in the closedvolume and an outer edge that is spaced outwardly from the inner edge,the user side of the sealing member may have a width extending betweenthe inner edge and the outer edge and, when the user is wearing thefilter mask, only a portion of the user side of the sealing member mayabut the face of a user.

In any embodiment, the portion of the user side of the sealing memberthat abuts the face of a user may comprise the inner edge.

In any embodiment, the sealing member may comprise a closed cell foamhaving a stiffness of 10-80 on shore 00 scale.

In any embodiment, the sealing member may have a user side that abutsthe face of the user when the user is wearing the filter mask, the userside of the sealing member may have an inner edge located in the closedvolume and an outer edge that is spaced outwardly from the inner edge,the user side of the sealing member may have a width extending betweenthe inner edge and the outer edge wherein at least 10% of the width ofthe user side of the sealing member may be located in the volume.

In any embodiment, the sealing member may have a user side that abutsthe face of the user when the user is wearing the filter mask, the userside of the sealing member may have an inner edge located in the closedvolume and an outer edge that is spaced outwardly from the inner edge,the user side of the sealing member may have a width extending betweenthe inner edge and the outer edge wherein at least 15% of the width ofthe user side of the sealing member may be located in the volume.

In any embodiment, when the filter mask is worn by a user, the closedvolume may cover the mouth, nose and eyes of the user.

In accordance with another aspect of this design, which may be used byitself or with one or more other aspects disclosed herein, the filtermask includes a face plate that is permanently attached to the filtermask. The face plate provides an open volume that overlies the eyes ofthe user. An advantage of this design is that the face plate improvesthe protection of the user's eyes from contaminates, while stillallowing air flow in front of the user's face to improve the comfort ofthe user.

In accordance with this aspect, there is provided a filter maskcomprising:

-   -   a) a mask body having a user side that faces towards a face of        the user when the filter mask is worn by a user wherein, when        the filter mask is worn by a user, the filter mask abuts the        face of the user whereby a closed volume that covers the mouth        and nose of the user is provided; and,    -   b) a face plate that is permanently attached to the filter mask        wherein, when the filter mask is worn by a user, the face plate        overlies the eyes of the user whereby an open volume that        overlies the eyes of the user is provided.

In any embodiment, the face plate may be integrally molded with aportion of the mask body.

In any embodiment, the face plate and the portion of the mask body maybe transparent.

In any embodiment, when the filter mask is worn by a user, the portionof the mask body that overlies the mouth of the user may be transparent.

In accordance with another aspect of this design, which may be used byitself or with one or more other aspects disclosed herein, the filtermask includes a face plate that is integrally formed as part of the maskbody. An advantage of this design is that the speed and/or ease ofmanufacturing the filter mask may be improved. Another advantage of thisdesign is that by integrally forming the face plate with the mask bodythe seal between the mask body and the face plate may be improved sincethe seam between the face plate and the mask body has been eliminated.

In accordance with this aspect, there is provided a filter maskcomprising:

-   -   a) a mask body having a user side that faces towards a face of        the user when the filter mask is worn by a user wherein, when        the filter mask is worn by a user, the filter mask abuts the        face of the user whereby a closed volume that covers the mouth        and nose of the user is provided; and,    -   b) a face plate that is integrally formed as part of the mask        body wherein, when the filter mask is worn by a user, the face        plate overlies the eyes of the user whereby an open volume that        overlies the eyes of the user is provided.

In any embodiment, the face plate and a portion of the mask body thatoverlies the mouth of the user when the filter mask is worn by the usermay be transparent.

In any embodiment, the face plate and a portion of the mask body thatoverlies the mouth and nose of the user when the filter mask is worn bythe user may be transparent.

In accordance with another aspect of this design, which may be used byitself or with one or more other aspects disclosed herein, the air inletto the filter mask faces downwardly. The air inlet may be rearward ofthe face of a person wearing the filter mask or below the mouth of aperson wearing the mask. For example, if the air inlet is rearward ofthe face of a person wearing the filter mask, then the air inlet mayface towards the top of a person's head. Alternately, if the filterassembly is below the mouth of a user (e.g., in front of the chin or aperson wearing the filter mask) then the air inlet may face the ground.Accordingly, for example, the plane of the opening to the filter mask(the air inlet) may be perpendicular or generally perpendicular to theground when a person is wearing the filter mask. Therefore, the airtreatment member may be protected from, e.g., rain. Therefore, the airtreatment member is less likely to become wet if the filter mask is wornby a person when it is raining.

In accordance with this aspect, there is provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user; and,(b) a filter assembly that is suitable for having a filter media housedtherein, the filter assembly having a port for airflow therethrough asthe user breathes, wherein when the filter mask is worn by a user andthe user is standing upright, the port faces downwardly.

In any embodiment, when the user is wearing the mask, the filterassembly may be positioned below a mouth of the user and a portion ofthe mask body overlying the mouth may be transparent.

In any embodiment, the filter media may be removably receivable in thefilter assembly while the filter mask is worn by a user.

In any embodiment, the filter media may be removable through the port.

In any embodiment, the filter assembly may have a cavity in which thefilter media may be removably receivable and the port may be located atthe entrance to the cavity.

In any embodiment, the cavity may have an insertion direction for thefilter media, the cavity may be defined by walls and, when the filtermedia is positioned in the cavity, the filter media may be recessedinwardly of the port in the insertion direction and a portion of thewalls may define a descending lip which may extend outwardly of thefilter media in a direction that is opposite to the insertion direction.

In any embodiment, the port may be used for inhalation and exhalation.

In any embodiment, the filter media may be provided in a filtercartridge and the filter cartridge may have an inhalation side and anexhalation side.

In any embodiment, the filter media may be provided in a filtercartridge and, when the filter cartridge is positioned in the filterassembly, a portion of two opposed sides of the filter cartridge may bevisible whereby the portions provide gripping surfaces for removal ofthe filter cartridge from the filter assembly.

In any embodiment, the filter assembly may have a cavity in which thefilter cartridge may be removably receivable, the cavity may have aninsertion direction for the filter cartridge, the cavity may be definedby walls that extend in the insertion direction and the portion of twoopposed sides of the filter cartridge may extend outwardly of two of thewalls of the cavity when the filter cartridge is inserted in the cavity.

In any embodiment, the filter media may be provided in a filtercartridge and the filter cartridge may have a handle.

In any embodiment, the filter assembly may be openable.

In any embodiment, the filter assembly may have a cavity in which thefilter cartridge may be removably receivable, the cavity may have aninsertion direction for the filter cartridge, the cavity may be definedby walls that extend in the insertion direction and one of the walls maybe moveable between a closed position in which the filter cartridge maybe secured in the cavity and a removal position in which the filtercartridge may be removable from the cavity.

In any embodiment, the filter cartridge may be lockingly receivable inthe cavity.

In any embodiment, the filter cartridge may have a first engagementmember which may mate with a second engagement member when the filtercartridge is positioned in the cavity and the one of the walls is in theclosed positioned whereby the filter cartridge may be lockinglyreceivable in the cavity.

In any embodiment, the one of the walls may be pivotally mounted to thefilter assembly.

In any embodiment, the one of the walls may have a guide surface.

In any embodiment, the filter media may be provided in a filtercartridge and the filter material may be removably receivable in thefilter cartridge.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, the filter mask may have asolid/liquid outlet and storage container. For example, in the case ofemesis, the vomit from a patient who is wearing the filter mask may flowdownwardly into the storage container. An advantage of this design isthat the air treatment member is spaced from the vomit and will not besoiled by the vomit and may therefore continue to function even afterthe patient has vomited.

In accordance with another aspect of this design, the faceplate may beprovided with a speaker, such as a vibratory diaphragm, so as to enablea medical worker to more clearly understand what a patent says.Alternately, the face plate itself may be designed as a vibratorydiaphragm or as a resonant member so as to better transmit the wordsthat are said by a patient wearing the mask. Alternately, the filtermask may include a speaker that may be connected, e.g., wirelessly suchas by Bluetooth™ to a remote speaker (e.g., a mobile phone).

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, the filter mask has areplaceable filter assembly. Accordingly, the mask body of a filter maskmay have a filter assembly that is removably attachable thereto. Forexample, the mask body may have one or more inlet and outlet ports thatare removably connectable to one or more inlet and outlet ports on afilter assembly. Alternately, the filter mask may have a recess orcavity or the like for removably receiving a filter holder (which mayalso be referred to as a filter cartridge). The replaceable filterassembly or filter holder may have any one or more features disclosedherein. An advantage of this design is that the filter assembly orfilter holder may be replaced with a new or a cleaned filter assembly orfilter holder while the person continues to wear the mask. Also inaccordance with this aspect, different filter assemblies or filterholders may be provided. For example, the filter assemblies or filterholders may use different filter materials and/or may provide differinglevels of filtration. Accordingly, a mask body may be modified toprovide enhanced filtration by only changing the filter assembly or thefilter media or the filter holder. Also, due to supply constraints,there may be a limited supply of certain filter materials. Accordingly,a filter assembly or filter holder having a desired degree of filtrationmay be fabricated from available filter materials without concern forthe size or configuration of a filter housing. According, filterassemblies or filter holders using different filter materials anddifferent configurations or sizes may be useable with a common mask bodyby, e.g., configuring the inlet and outlet ports of a filter assembly tomate with those of an existing mask body by sizing a filter holder to beslideably receivable in a recess of a filter mask. Alternately,different sized filter masks (e.g., an adult sized mask and a childsized mask) may use the same filter holder.

In accordance with this aspect, there is provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user; and,(b) a filter assembly having a cavity in which a filter cartridge isremovably receivable, wherein a filter material is removably receivablein the filter cartridge.

In any embodiment, the filter cartridge may be openable whereby thefilter media may be removable when the filter cartridge is opened.

Optionally, a mask body may have two or more filter assembliesconcurrently attachable thereto such that, at any one time, the maskbody may have two filter assemblies attached thereto. For example, onefilter assembly may be attached to one or more inlet and outlet portsand another filter assembly may be attached to a one or more alternateinlet and outlet ports. A valve may be provided to selectively close theflow path between one of the filter assemblies and the mask body or eachof the filter assemblies and the mask body. An advantage of this designis that one of the filter assemblies may be used as a backup filterassembly in case the other filter assembly is damaged. Alternately, theair flow path from a filter assembly to the mask body may be closedwhile a filter assembly is being replaced.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, a filter assembly maycomprise a multilayer filter. Accordingly, a plurality of filter mediahaving different pore sizes may be used. An advantage of this design isthat the filter media that is provided to filter a biologicalcontaminant (the biological filter media) may have one or more porousfilter members upstream thereof when a person inhales. The more porousmaterial may therefore protect the biological filter media fromparticulate contaminants in the ambient and/or moisture in the ambient.Alternately, or in addition, the biological filter media may have one ormore porous filter members upstream thereof when a person exhales. Themore porous material may therefore protect the biological filter mediafrom particulate contaminants in the air and/or moisture in the air whena person exhales. The more porous filter media may be removable forcleaning or replacement. Such more porous material may comprise foam(e.g., a reticulated polyurethane foam) and/or felt. The more porousfilter media will inhibit or prevent larger particulate matter fromtravelling to the smaller pore sized biological filter material.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, one or more filter membersof a filter assembly may be positioned in a filter holder with a portionof the filter material extending outwardly of the filter holder. Forexample, the filter holder may have an opening on one side and thefilter member may extend through the opening. Optionally, an opening isalso provided on an opposed side of the filter holder and the filtermember may extend outwardly through each of the opposed sides of thefilter holder. An advantage of this design is that the filter member maybe slid into position in the filter holder by inserting the filtermember into the opening on a first side of the filter holder and thensliding the filter member longitudinally through the filter holder sothat a portion of the filter member extends outwardly of the secondopposed end of the filter holder while another portion of the filtermember is positioned outwardly of the first side of the filter holder.The filter member may be secured in position in the filter holder byapplying an adhesive, such as glue from a hot melt glue gun and/orsilicone, at a location at which the filter member exits the filterholder. For example, the adhesive may be applied on the exterior of thefilter holder along the perimeter of the opening through which thefilter material extends. An advantage of this design is that theadhesive (the sealing member) is visible from the exterior of the filterholder so that the seal may be easily inspected.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, the mask body may have asealing member that includes a deformable portion that seals around thetemples of eyeglasses. An advantage of this design is that the mask bodymay provide a full seal for the face of a user even if the user iswearing glasses. Alternately, or in addition, a deformable member may beprovided for placement on the temples of eyeglasses so as to form a sealwhen the mask is placed on the face of a person who is wearing glasses.Such an embodiment may be used if the face plate of the filter maskoverlies the eyes of a person wearing the filter mask. Alternately, ifthe filter mask only overlies the mouth and nose of a person wearing thefilter mask, then the upper end of the mask body may have recessedportions into which the eyeglasses of a person may seat.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, the mask body may have asealing member wherein only a portion of the sealing member, e.g., aninner edge, may contact the face of a user. For example, the anglebetween the user side of a sealing member and the face of a user may besufficiently acute such that only a portion of the user side of the faceseal abuts the face of a user and most of the user side of the sealingmember may be spaced from the face of a user. Accordingly, the contactbetween the seal and the face of a user may be concentrated on a smallarea of the sealing member. Therefore, if the sealing member isrelatively stiff (e.g., 10-80 or 35-50 on shore 00 scale), a good sealmay still be provided.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, the mask may have anopenable port through which a biological sample may be taken. Forexample, a lower portion of the face plate may have an openable portthrough which a doctor may insert a swab to take a sample from, e.g., aperson's mouth or nose. Alternately, a port may extend through thefilter assembly or filter holder. Optionally, a deformable membrane or aduck bill valve may be provided proximate the port. The membrane maydeform or the valve may open to permit the swab to extend therethrough.Alternately, or in addition, a sealing member may be provided on thestem of the, e.g., swab. Accordingly, as the swab is inserted throughthe opened port, the sealing member (e.g., silicon) may abut the outerside of the port to seal the port as the swab is inserted. Anotheradvantage of the openable port is that the person may open the port todrink through a straw.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, one or more fans (e.g., suchas a fan that may be typically used to cool a CPU and which maytherefore be referred to as a CPU fan), may be incorporated into themask and, optionally, into the filter assembly. The one or more fans maybe powered by an on board energy storage member, such as a battery or acapacitor, which may be rechargeable in situ and/or removable forreplacement or recharging. The one or more fans may be used to assistduring inhalation and/or exhalation but may optionally only be used forassisting with inhalation. An advantage of this design is that a user isprovided with assistance to draw air through the filter media. If thefan is provided in the exhalation path, then the fan may utilize apropeller fan blade design.

In accordance with this aspect, there is provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user; and(b) a filter assembly that is suitable for having a filter media housedtherein, the filter assembly having a port for airflow therethrough,wherein a first fan is provided downstream of the port in a direction offlow of air during inhalation and the first fan comprises a motor and apropeller.

In any embodiment, the port may be used for inhalation and exhalationwhereby air may travel past the first fan during both inhalation andexhalation.

In any embodiment, the filter mask may have an inhalation passage and anexhalation passage and the first fan may be provided in the inhalationpassage.

In any embodiment, a second fan may be provided in the exhalationpassage.

In any embodiment, the filter media may be provided in a filtercartridge, the filter cartridge may have an inhalation side and anexhalation side and the first fan may be provided on the inhalationside.

In any embodiment, the first fan may produce an air flow of 6 to 18liters/minute.

In any embodiment, the filter mask may further comprise an energystorage member operably connected to the fan and the energy storagemember may be rechargeable while positioned in the filter mask.

In any embodiment, the filter mask may have a charging port.

In any embodiment, the filter media may comprise a HEPA filter media.

In any embodiment, the filter media may be provided in a filtercartridge, the filter cartridge may have first and second opposed sidesand walls extending between the opposed sides wherein the walls andopposed sides may define a cavity in which the filter media ispositioned, the first opposed side may have a first port for air flowtherethrough, the second opposed side may have a second side surfacehaving a second port for air flow therethrough wherein, duringinhalation, air may travel from the first port, through the filter mediaand through the second port, the fan may be provided downstream of thesecond port and the second port may be provided on only one end of thesecond side surface.

In any embodiment, the second port may occupy less than 50% of thesecond side.

In any embodiment, the first side may be open and may comprise the firstport.

In any embodiment, during inhalation, the cavity may have a downstreamside and the downstream side of the cavity may include a header.

In any embodiment, the header may be positioned between the filter mediaand the second side surface.

In accordance with this aspect, there is also provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user; and,(b) a filter assembly that is suitable for having a filter media housedtherein, wherein the filter mask has an inhalation passage and anexhalation passage, the filter media is provided in the inhalationpassage and a first fan is provided in the inhalation passage.

In any embodiment, the filter media may be also provided in theexhalation passage and a second fan may be provided in the exhalationpassage.

In any embodiment, the filter mask may further comprise an energystorage member operable connected to the fan and the energy storagemember may be rechargeable while positioned in the filter mask.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, there is provided a filtermask having a filter cartridge with first and second ports for airflowand a fan provided downstream of the second port wherein the second portoccupies less than 50% of a second side of the filter cartridge. Anadvantage of this design is that the same port may be used forinhalation and exhalation. A common passageway may allow the fan to beused for regenerative energy recovery.

In accordance with this aspect, there is provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user;(b) a filter cartridge having first and second opposed sides and wallsextending between the opposed sides wherein the walls and opposed sidesdefine a cavity in which the filter media is positioned, the firstopposed side has a first port for air flow therethrough, the secondopposed side has a second side surface having a second port for air flowtherethrough wherein, during inhalation, air travels from the firstport, through the filter media and through the second port; and,(c) a fan provided downstream of the second port wherein the second portis provided on only one end of the second side surface such that thesecond port occupies less than 50% of the second side.

In any embodiment, the first side may be open and may comprise the firstport.

In any embodiment, during inhalation, the cavity may have a downstreamside and the downstream side of the cavity may include a header that maybe positioned between the filter media and the second side surface.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, the separate inhalation andexhalation channels may be provided. For example, one or more inhalationchannels may be provided on one lateral side of the mask and one or moreexhalation channels may be provided on the other opposed lateral side ofthe mask. Therefore, during inhalation, air may be drawn downwardly onone lateral side of the volume between the mask and the face of the userand, during exhalation, air may travel upwardly along the opposedlateral side of the volume. An advantage of this design is that acirculation pattern may be set up in the volume. Such a circulationpattern will assist in reducing carbon dioxide build up in the volume.In addition, the circulation may assist in reducing, inhibiting orpreventing fog build up on the inside of the faceplate of the mask.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, water may be added to theair entering the filter mask, which may thereby cool the air inhaled bya person wearing the filter mask. For example, if a multilayer filter isused, the outer more porous filter media (e.g., foam), may be providedwith water.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, the frame of a filter maskthat can removably receive a filter holder may be made of a closed cellfoam or a reinforced closed cell foam. An advantage of this design isthat the frame of a filter mask that can removably receive a filterholder may be made of a flexible material. Also, a closed cell foam,which is a non-traditional frame material, may be used. In alternateembodiments, the frame member may be made of molded plastic or stampedmetal. A plastic or stamped metal frame may include a spring sectionwhereby the frame may provide a spring force to bias the sealing memberor a contact portion of the sealing member against the face of a user.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, copper, silver zinc or amixture thereof may be provided, e.g., vapour deposited or plasmasprayed) on some or all of the frame to provide an anti-microbialproperty to the frame.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, copper, silver zinc or amixture thereof may be provided to a formed foam, e.g., an open cellfoam, to reduce the pore size of the open cells and thereby increase thedegree of filtration provided by the treated open cell foam. Forexample, nanoparticles of copper, silver, zinc, or a mixture thereof maybe introduced into foam to form a metal coated foam filter media orvapour deposited on foam to form a metal coated foam filter media orfoam may be subjected to a plasma spray to form a metal coated foamfilter media. For example, an open cell foam such as polypropylene, with0.2-100, 0.5-50 or 3-25 micron pores prior to deposition, can beconverted to have 0.05-0.1 micron pores after deposition.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, there is provided a filtermask having a face plate or face shield that is spaced from the face ofa person wearing the filter mask. Such a face plate or face shield maybe a separate face shield that overlies the upper face of a user so asto overlie the eyes of a user. Such a face plate or face shield may bemountable, and optionally removably mountable, to the filter mask. Anadvantage of this design is that the face plate may provide additionalprotection to the user by protecting the eyes of the user from airbornecontaminates, as described previously.

In accordance with this aspect, there is provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user;(b) a filter assembly removably mounted to the mask body, the filterassembly comprising a fan and a cavity that is suitable for having afilter media housed therein; and,(c) a face plate,wherein an air flow passage extends between an inlet port of the filterassembly and the mask body.

In any embodiment, the face plate may be removably mounted to the filtermask.

In any embodiment, the face plate may be removably mounted to the maskbody.

In any embodiment, the face plate may be removably mounted between thefilter assembly and the mask body.

In any embodiment, the filter mask may further comprise a mountingassembly removably mounting the filter assembly to the mask body and themounting assembly may extend through an opening in the face plate.

In any embodiment, the mounting assembly may comprise a first mountingmember provided on the filter assembly and a second mounting memberprovided on the mask body and the mounting members may define a portionof the air flow passage.

In any embodiment, the filter assembly may be rotatably mounted to themask body.

In any embodiment, the face plate may be spaced from a face of the user.

In any embodiment, when the user is wearing the filter mask, the faceplate may be positioned on a side of the mask body opposed to the faceof a user.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, there is provided a filtermask having a face plate that is removably mounted to the filter mask.An advantage of this design is that the face plate may be offset fromthe face of the user, reducing the discomfort of the user by increasingthe possibility of air flow across the user's face while protecting theuser from airborne contaminates.

In accordance with this aspect, there is provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user;(b) a filter assembly removably mounted to the mask body, the filterassembly comprising a cavity that is suitable for having a filter mediahoused therein; and,a face plate that plate is removably mounted between the filter assemblyand the mask body.

In any embodiment, the filter mask may further comprise a mountingassembly removably mounting the filter assembly to the mask body and themounting assembly may extend through an opening in the face plate.

In any embodiment, the mounting assembly may comprise a first mountingmember provided on the filter assembly and a second mounting memberprovided on the mask body and the mounting members may define a portionof the air flow passage.

In any embodiment, the filter assembly may be rotatably mounted to themask body.

In any embodiment, the face plate may be spaced from a face of the user.

In any embodiment, when the user is wearing the filter mask, the faceplate may be positioned on a side of the mask body opposed to the faceof a user.

In accordance with another aspect, which may be used by itself or withone or more other aspects disclosed herein, there is provided a filtermask having a removable face plate. An advantage of this design is thatthe face plate may be easily removed for cleaning, thereby improving theability of the mask to be sanitized.

In accordance with this aspect, there is provided a filter maskcomprising:

(a) a mask body which, when worn by a user, abuts the face of the userand covers the mouth and nose of the user;(b) a filter assembly removably mounted to the mask body, the filterassembly comprising a cavity that is suitable for having a filter mediahoused therein; and,a face plate that plate is removably mounted to the filter mask.

In any embodiment, the face plate may be removably mounted to the maskbody.

In any embodiment, the face plate may be removably mounted between thefilter assembly and the mask body.

In any embodiment, the filter mask may further comprise a mountingassembly removably mounting the filter assembly to the mask body and themounting assembly may extend through an opening in the face plate.

In any embodiment, the filter assembly may be rotatably mounted to themask body.

It will be appreciated by a person skilled in the art that an apparatusor method disclosed herein may embody any one or more of the featurescontained herein and that the features may be used in any particularcombination or sub-combination.

These and other aspects and features of various embodiments will bedescribed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the described embodiments and to show moreclearly how they may be carried into effect, reference will now be made,by way of example, to the accompanying drawings in which:

FIG. 1 is a side view of a person wearing a filter mask;

FIG. 2 is a cross-sectional view of a first embodiment of a filterapparatus for the filter mask of FIG. 1;

FIG. 3 is a cross-sectional view of a second embodiment of a filterapparatus for the filter mask of FIG. 1;

FIG. 4 is a cross-sectional view of a third embodiment of a filterapparatus for the filter mask of FIG. 1

FIG. 5 is a front perspective view of an alternate embodiment of afilter mask wherein the strap for securing the filter mask in positionhas been omitted;

FIG. 6 is a rear perspective view of the filter mask of FIG. 5;

FIG. 7 is a rear perspective view of the filter mask of FIG. 5 with thefilter assembly removed;

FIG. 8 is a rear perspective view of the mask body of the filter mask ofFIG. 5;

FIG. 9 is a front perspective view of the mask body of the filter maskof FIG. 5;

FIG. 10 is a rear perspective view of the filter mask of FIG. 5 showingthe inlet and outlet ports of the filter assembly removed;

FIG. 11 is a cross section along the line 11-11 of the filter assemblyof FIG. 5;

FIG. 12 is an enlarged cross section along the line 11-11 of the filterassembly and the upper portion of the filter mask of FIG. 5;

FIG. 13 is a front perspective view of a further alternate embodiment ofa filter mask wherein the strap for securing the filter mask in positionhas been omitted and two separate filter assemblies are provided;

FIG. 14 is a front perspective view if an alternate mask body with anopenable port provided in the open position and a sampling swab with asealing member;

FIG. 15 is a front perspective view of a further alternate embodiment ofa filter mask wherein the strap for securing the filter mask in positionhas been omitted and two separate filter assemblies are provided;

FIG. 16 is a front perspective view of the alternate filter mask of FIG.15 wherein one of the air flow conduits has been rotated to close avalve in the air flow conduit and the filter assembly of that air flowconduit has been removed for replacement;

FIG. 17 is a perspective view of a pair of eye glasses with sealingmembers on the temples;

FIG. 18 is an enlarged end view of the portion of the seal of region Aof the filter mask of FIG. 1 with the temple of a pair of eye glassespositioned as the eye glasses would be worn by the person wearing themask in FIG. 1;

FIG. 19 is a cross section along the line 11-11 of a further alternateembodiment of a filter assembly of FIG. 5;

FIG. 20 is a front perspective view of a further alternate embodiment ofa filter mask;

FIG. 21 is a side elevation view of the filter mask of FIG. 20;

FIG. 22 is a front elevation view of the filter mask of FIG. 20;

FIG. 23 is a top plan view of the filter mask of FIG. 20;

FIG. 24 is a front perspective view of the filter mask of FIG. 20 withthe filter assembly removed;

FIG. 25 is a top perspective view of the filter mask of FIG. 20 with thefilter assembly removed, the top of the filter assembly removed and thefilter assembly being glued to the mask;

FIG. 26 is a rear perspective view of the filter mask of FIG. 20 withthe filter assembly being glued to the mask;

FIG. 27 is a cross-sectional view along line 27-27 in FIG. 20;

FIG. 28 is a cross-sectional view along line 28-28 in FIG. 20

FIG. 29 is a side perspective view of the filter mask of FIG. 20 withthe filter holder being transparent;

FIG. 30 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask having fan assistedinhalation and showing a circulation pattern during typical inhalation;

FIG. 31 is a cross-sectional view along line 28-28 in FIG. 20 of thealternate filter mask of FIG. 30 showing a circulation pattern duringdeep inhalation;

FIG. 32 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 33 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 34 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 35 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 36 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 37 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 38 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 39 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 40 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 41 is a cross-sectional view along line 28-28 in FIG. 20 of afurther alternate embodiment of a filter mask;

FIG. 42 is an exploded view of a filter holder and a filter member;

FIG. 43 is a perspective view of the filter member of FIG. 42 being slidinto the filter holder of FIG. 42;

FIG. 44 is a perspective view of the filter member of FIG. 42 fullyinserted into the filter holder of FIG. 42;

FIG. 45 is a perspective view of the filter member of FIG. 42 beingglued to the filter holder of FIG. 42;

FIG. 46 is a top perspective view of the filter member of FIG. 42 havingbeen glued to the filter holder of FIG. 42;

FIG. 47 is a perspective view of a removable filter member beinginserted into the top of the filter holder of FIG. 42;

FIG. 48 is a perspective view of the filter holder of FIG. 42 with theremovable filter member of FIG. 47 positioned therein;

FIG. 49 is a perspective view of a top lid being placed on the top ofthe filter holder of FIG. 42;

FIG. 50 is an exploded view of two elastic securing members positionedto be placed on the filter holder of FIG. 42 which has the top lid ofFIG. 49 placed thereon;

FIG. 51 is a perspective view of the filter assembly of FIG. 50 in afully assembled configuration;

FIG. 52 is a fully exploded view of the filter assembly of FIG. 51

FIG. 53 is a front perspective view of a further alternate embodiment ofa filter mask;

FIG. 54 is a side elevation view of the filter mask of FIG. 53;

FIG. 55 is a top plan view of the filter mask of FIG. 53;

FIG. 56 is a front elevation view of the filter mask of FIG. 53;

FIG. 57 is a rear perspective view of the filter mask of FIG. 53;

FIG. 58 is a front perspective view of the filter mask of FIG. 53 withthe filter assembly removed;

FIG. 59 is a rear perspective view of the filter mask of FIG. 53 withthe filter assembly removed

FIG. 60 is a front perspective view of a further alternate embodiment ofa filter mask;

FIG. 61 is a perspective cross-sectional view along the line 61-61 inFIG. 60;

FIG. 62 is an elevation cross-sectional view along the line 61-61 inFIG. 60;

FIG. 63 is a cross-sectional view along the line 63-63 in FIG. 60;

FIG. 64 is a cross-sectional view along the line 64-64 in FIG. 60;

FIG. 65 is a perspective cross-sectional view along the line 61-61 inFIG. 60 wherein the inlet port has a duck bill valve;

FIG. 66 is a perspective cross-sectional view along the line 61-61 inFIG. 60 wherein the outer filter housing has been removed to enable aperson to use a drinking straw;

FIG. 67 is a side view of a side panel of a disposable filter holderwhich may be used in the embodiments of FIGS. 53 and 60;

FIG. 68 is a side view of the side panel of FIG. 67 with filter mediasecured in the side panel;

FIG. 69 is a top perspective view of a disposable filter holder usingtwo side panels of FIG. 67;

FIG. 70 is a front perspective view of a filter mask with a disposablefilter cartridge being inserted;

FIG. 71 is a rear perspective view of the filter mask of FIG. 70 withthe disposable filter cartridge fully inserted;

FIG. 72 is a front perspective view of a further alternate embodiment ofa filter mask wherein the straps for securing the filter mask inposition has been omitted;

FIG. 73 is a front view of the filter mask of FIG. 72;

FIG. 74 is a side view of the filter mask of FIG. 72;

FIG. 75 is a top view of the filter mask of FIG. 72;

FIG. 76 is a rear view of the filter mask of FIG. 72;

FIG. 77 is a bottom perspective view of the filter mask of FIG. 72;

FIG. 78 is a bottom perspective view of the filter mask of FIG. 72 witha filter cartridge partially removed;

FIG. 79 is a bottom perspective view of the filter mask of FIG. 72 witha filter cartridge fully removed;

FIG. 80 is a front perspective view of the filter mask of FIG. 72 with afilter cartridge fully removed;

FIG. 81 is a bottom perspective view of the filter mask of FIG. 72 witha foam filter fully removed;

FIG. 82 is a top perspective view of a filter assembly of the filtermask of FIG. 72 with the front cover and a lid of the filter assemblyremoved;

FIG. 83 is a perspective cross-sectional view along the line 83-83 inFIG. 75;

FIG. 84 is a front perspective exploded view of the filter mask of FIG.72;

FIG. 85 is a rear perspective exploded view of the filter mask of FIG.72;

FIG. 86 is a front perspective view of a further alternate embodiment ofa filter mask having a face plate offset from the face of a user,wherein the straps for securing the filter mask in position has beenomitted;

FIG. 87 is a front view of the filter mask of FIG. 86;

FIG. 88 is a side view of the filter mask of FIG. 86;

FIG. 89 is a side cross-sectional view along the line 89-89 in FIG. 86;

FIG. 90 is a front exploded view of the filter mask of FIG. 86;

FIG. 91 is a rear exploded view of the filter mask of FIG. 86;

FIG. 92 is a front view of a further alternate embodiment of a filtermask having a face plate offset from the face of a user, wherein thestraps for securing the filter mask in position has been omitted and theuser is wearing a hardhat;

FIG. 93 is a side view of the filter mask of FIG. 92;

FIG. 94 is a side cross-sectional view along the line 94-94 of FIG. 92;

FIG. 95 is a front perspective view of a further alternate embodiment ofa filter mask having a face plate offset from the face of a user;

FIG. 96 is a front perspective view of the filter mask of FIG. 95 wornby a user;

FIG. 97 is a front perspective view of the filter mask of FIG. 95 wornby a user;

FIG. 98 is a rear cross-sectional view along the line 97-97 in FIG. 97of a further embodiment of a filter assembly having two fans;

FIG. 99 is a rear perspective cross-sectional view along the line 97-97in FIG. 97 of the filter assembly of FIG. 98;

FIG. 100 is a rear perspective cross-sectional view along the line 97-97in FIG. 97 of the filter assembly of FIG. 98 with airflow illustrations;

FIG. 101 is a front perspective view of a further alternate embodimentof a filter mask having a mask body with a transparent portion;

FIG. 102 is a front view of the filter mask of FIG. 101;

FIG. 103 is a front perspective view of the filter mask of FIG. 101 whenworn by a user;

FIG. 104 is a front view of the filter mask of FIG. 101 when worn by auser;

FIG. 105 is a front perspective view of a further alternate embodimentof a filter mask having a transparent mask body;

FIG. 106 is a sectional view of the filter mask of FIG. 105 along theline 106-106 in FIG. 105;

FIG. 107 is a sectional view of the filter mask of FIG. 105 along theline 107-107 in FIG. 105;

FIG. 108 is a rear perspective view of the filter mask of FIG. 105;

FIG. 109 is a partial bottom perspective view of the filter mask of FIG.105;

FIG. 110 is a front perspective view of the filter mask of FIG. 105 whenworn by a user;

FIG. 111 is a front view of the filter mask of FIG. 105 when worn by auser;

FIG. 112 is a side view of the filter mask of FIG. 105 when worn by auser;

FIG. 113 is a front perspective view of a further alternate embodimentof a filter mask having a face plate when worn by a user;

FIG. 114 is a front view of the filter mask of FIG. 113 when worn by auser;

FIG. 115 is a side view of the filter mask of FIG. 113 when worn by auser;

FIG. 116 is a front perspective view of a further alternate embodimentof a filter mask having a face plate when worn by a user;

FIG. 117 is a rear perspective view of the filter mask of FIG. 116 whenworn by a user;

FIG. 118 is a front perspective view of a further embodiment of a filterassembly;

FIG. 119 is a front perspective exploded view of the filter assembly ofFIG. 118;

FIG. 120 is a bottom perspective exploded view of the filter assembly ofFIG. 118;

FIG. 121 is a schematic view of an exemplary embodiment of a steamcleaning system;

FIG. 122 is a schematic view of a further exemplary embodiment of asteam cleaning system;

FIG. 123 is a front perspective view of a further alternate embodimentof a filter mask having a face plate;

FIG. 124 is a front perspective view of the filter mask of FIG. 123 withthe face plate removed;

FIG. 125 is a rear perspective view of the filter mask of FIG. 123 withthe face plate removed;

FIG. 126 is a front exploded view of the filter mask of FIG. 123;

FIG. 127 is a front perspective view of a further alternate embodimentof a filter mask having a mask body with a face plate when worn by auser;

FIGS. 128A and 128B are front and rear views respectively of the maskbody and face plate of FIG. 127;

FIGS. 129A and 129B are top and side views respectively of the mask bodyand face plate of FIG. 127;

FIG. 130 is a rear perspective view of the mask body and face plate ofFIG. 127;

FIG. 131 is a bottom perspective view of the mask body and face plate ofFIG. 127;

FIG. 132 is a front exploded view of the filter mask of FIG. 127;

FIG. 133 is a front perspective view of a further embodiment of a filterassembly;

FIG. 134 is a front exploded view of the filter assembly of FIG. 133;

FIG. 135 is a front perspective view of a further embodiment of a filterassembly;

FIG. 136 is a front exploded view of the filter assembly of FIG. 135;

FIG. 137 is a front view of an embodiment of a sealing member for use ina filter mask;

FIGS. 138A and 138B are rear perspective and side views, respectively,of a further embodiment of a sealing member for use in a filter mask;

FIG. 139 is a rear perspective view of a further embodiment of a filtermask having an insert;

FIG. 140 is a front exploded view of the filter mask of FIG. 139;

FIG. 141 is a front perspective view of a further alternate embodimentof a filter mask having a securing mechanism with rigid side portions;

FIG. 142 is a front perspective partially exploded view of the filtermask of FIG. 141;

FIG. 143 is a top view of the securing mechanism of FIG. 141;

FIG. 144 is a rear view of the securing mechanism of FIG. 141;

FIG. 145 is a front perspective view of a further alternate embodimentof a filter mask having a securing mechanism with rigid side portions,when worn by a user;

FIG. 146 is a top view of the filter mask of FIG. 145, when worn by auser; and

FIG. 147 is a side perspective view of a further alternate embodiment ofa filter mask having a securing mechanism with rigid side portions.

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the teaching of the presentspecification and are not intended to limit the scope of what is taughtin any way.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Various apparatuses, methods and compositions are described below toprovide an example of an embodiment of each claimed invention. Noembodiment described below limits any claimed invention and any claimedinvention may cover apparatuses and methods that differ from thosedescribed below. The claimed inventions are not limited to apparatuses,methods and compositions having all of the features of any oneapparatus, method or composition described below or to features commonto multiple or all of the apparatuses, methods or compositions describedbelow. It is possible that an apparatus, method or composition describedbelow is not an embodiment of any claimed invention. Any inventiondisclosed in an apparatus, method or composition described below that isnot claimed in this document may be the subject matter of anotherprotective instrument, for example, a continuing patent application, andthe applicant(s), inventor(s) and/or owner(s) do not intend to abandon,disclaim, or dedicate to the public any such invention by its disclosurein this document.

The terms “an embodiment,” “embodiment,” “embodiments,” “theembodiment,” “the embodiments,” “one or more embodiments,” “someembodiments,” and “one embodiment” mean “one or more (but not all)embodiments of the present invention(s),” unless expressly specifiedotherwise.

The terms “including,” “comprising” and variations thereof mean“including but not limited to,” unless expressly specified otherwise. Alisting of items does not imply that any or all of the items aremutually exclusive, unless expressly specified otherwise. The terms “a,”“an” and “the” mean “one or more,” unless expressly specified otherwise.

As used herein and in the claims, two or more parts are said to be“coupled”, “connected”, “attached”, or “fastened” where the parts arejoined or operate together either directly or indirectly (i.e., throughone or more intermediate parts), so long as a link occurs. As usedherein and in the claims, two or more parts are said to be “directlycoupled”, “directly connected”, “directly attached”, or “directlyfastened” where the parts are connected in physical contact with eachother. None of the terms “coupled”, “connected”, “attached”, and“fastened” distinguish the manner in which two or more parts are joinedtogether.

Furthermore, it will be appreciated that for simplicity and clarity ofillustration, where considered appropriate, reference numerals may berepeated among the figures to indicate corresponding or analogouselements. In addition, numerous specific details are set forth in orderto provide a thorough understanding of the example embodiments describedherein. However, it will be understood by those of ordinary skill in theart that the example embodiments described herein may be practicedwithout these specific details. In other instances, well-known methods,procedures, and components have not been described in detail so as notto obscure the example embodiments described herein. Also, thedescription is not to be considered as limiting the scope of the exampleembodiments described herein.

As used herein, the wording “and/or” is intended to represent aninclusive-or. That is, “X and/or Y” is intended to mean X or Y or both,for example. As a further example, “X, Y, and/or Z” is intended to meanX or Y or Z or any combination thereof.

General Description of a Mask Body

FIG. 1 exemplifies a person 16 wearing a filter mask 10. The filter maskcomprises a mask body 12 and a filter assembly 14.

The mask body 12 may be of any size and shape that covers at least themouth and nose of a user (see for example FIGS. 53-64 and 72-114) and,optionally, as exemplified, also covers the eyes of a person (see forexample FIGS. 1 and 5).

As exemplified in the embodiments of FIGS. 1 and 5, the mask body 12 mayhave a transparent face plate 20 mounted thereto that, together with themask body 12, defines a closed volume between the face of a user and themask in which the mouth, nose and eyes of a person wearing the mask arelocated and enables the face of a user to be visible. It will beappreciated that the face plate 20 may be any shape and/or size. Asexemplified in the embodiments of FIGS. 1 and 5, the face plate 20 maybe a single piece that extends over the face of the user and defines aclosed volume between the face of a user and the mask in which themouth, nose and eyes of a person wearing the mask are located.

As exemplified in the embodiments of FIGS. 1 and 5, the face plate hasan upper end 22 and a lower end 24. The face plate is optionally made ofa transparent material and is shaped to overlie and be spaced from theperson's mouth, nose and eyes so as to define a volume 28 between theinner surface of the face plate 20 and the face of the person.Accordingly, as exemplified in FIG. 1, the face plate may be sized andshaped so as to rest against the side of a person's face. Alternately,as exemplified in FIG. 5, mask body 12 may have a flange portion 88 thatseats against the face of a person wearing the filter mask 10. In theembodiments of FIGS. 5 and 20, face plate 20 is generally flat (i.e., itmay generally extend in a plane). Therefore, a side panel 18 is providedto position the face plate 20 so it is located outwards of the nose of aperson wearing the filter mask 10. As exemplified, side panel 18 extendsgenerally forwardly from flange portion 88. It will be appreciated thatside panel 18 may be made of any material and, optionally, side panel 18is transparent. For example, side panel 18 may be a one-piece moldedpart (e.g., it could be vacuum molded from a transparent plastic) thatis subsequently secured to flange portion 88 by, e.g., an adhesive,welding or the like.

Alternately, as exemplified in FIGS. 53-64, the mask body may not have atransparent face plate 20. Instead, the mask body 12 itself may overliethe mouth and nose of a user and define a closed volume 15 between theface of the user and the mask in which the mouth and nose of a personwearing the mask are located.

Alternately, as exemplified in FIGS. 101-104, the mask body 12 mayincorporate a transparent portion 13, which may be considered a faceplate 20, such that part or all of the mouth and, optionally part or allof the mouth and nose of a user are visible.

It will be appreciated that if the mask body 12 only creates a sealedvolume 15 in which the nose and mouth of a user and not the eyes arelocated, then a supplemental face plate 20 may be provided whichoverlies the eyes of the user (see for example FIGS. 86-91, 113-114, and123-132). In such a case, the supplemental face plate may be spaced infront of the eyes of a user and need not define a sealed volume in whichthe eyes are positioned. In other words, the face plate 20 may define anopen volume 28 that overlies the eyes of the user. It will beappreciated that, in some embodiments, the closed volume 15 may includethe face plate 20 such that the closed volume 15 covers the mouth, nose,and eyes of the user, as exemplified in FIG. 1.

Accordingly, as exemplified in the embodiments of FIGS. 86-97 and113-115, the face plate 20 may be offset from the face of a personwearing the mask such that the volume 28 between the inner surface ofthe face plate 20 and the face of the person may be open to theenvironment. For example, the face plate 20 may be positioned on a sideof the mask body 12 opposed to the face of the user, thereby offsettingthe face plate 20 from the face of the user. The volume 28 defined bythe face plate 20 of the embodiments of FIGS. 86-97 may allow forambient airflow in front of a person's face while the face plate 20protects the user's eyes. As exemplified, the mask body 12 does notprovide airflow, either inhalation or exhalation, into or near thevolume 28 or over the face plate 20. Positioning the air flow in and outof the filter mask 10 in a separate location than in the volume 28 mayreduce condensation build-up on the face plate 20 (which can occur dueto water vapor in the air exhaled by a user) and may reduce carbondioxide entrapment and build-up in the volume 28.

The filter mask may be secured to the head of a person by any meansknown in the mask arts. For example, as exemplified in FIGS. 1, 20, and95-97, one or more straps 30 may be provided to extend around a person'shead and secure the filter mask 10 in position on a person's face.

As exemplified in the embodiments of FIGS. 86-97, the face plate 20 maybe positioned such that the straps 30 secure the filter mask 10 inposition on a person's face while allowing for other protectiveequipment to be worn. For example, the filter mask 10 of FIGS. 86-97 mayallow a user to wear any form of head apparel without interfering withthe filter mask 10. As exemplified in FIGS. 93-98, a user may wear ahard hat for protection without interfering with the operation andcomfort of the filter mask 10.

As exemplified in FIGS. 5-12 and 20-29, flange portion 88 may beprovided with strap attachments 90. Strap attachments 90 have openings92 to which straps 30 (see FIGS. 20 and 95-97) may be attached. Anystrap attachment and strap known in the mask arts may be used. Further.The strap may be attached to any portion of the filter mask 10. In someembodiments, the straps 30 may be at least partially see-through. Forexample, in some embodiments, the straps 30 may be transparent.

Mask Body

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the mask body may be made ofa flexible material. An advantage of this design is that the mask bodymay be made of, e.g., a closed cell foam or a closed cell foam that isreinforced.

An N-95 mask may be made of an N-95 filter media that is molded orformed into a desired shape for a mask. Such a design uses more filtermaterial than is required. When biological filter material is in demand,then it is advantageous to use only an amount of biological filtermaterial that is required for filtration. Accordingly, a mask body ormask frame may be provided which is made of an alternate material andthe biological filter material may be removably receivable in, orremovably attachable to, the mask body.

Closed cell foams are readily available and may be used by themselves orwith one or more reinforcing layers to provide a mask body to removablyreceive a biological filter material. Closed cell foams may berelatively stiff compared to an open cell foam. For example, a closedcell foam may have a stiffness of, e.g., 10-80 or 35-50 on shore 00scale. Accordingly, a closed cell foam may be used by itself as the maskbody. An advantage of this design is that the mask body by itself may bethe closed cell foam (e.g., sealing member 26).

Alternately, as exemplified in FIGS. 53-64, 87-98, and 101-117 the maskbody may comprise a substrate 174 to which a closed cell foam isprovided. Optionally the closed cell foam may be sealing member 26 (asexemplified in FIGS. 53-64) or an alternate sealing member may beprovided, e.g., to the inner surface of the closed cell foam. Asexemplified in FIGS. 53-64 87-98, and 101-117 substrate 174 is formedinto a desired shape and a mask body side 27 or the sealing member 26 ismounted thereto, such as by an adhesive, welding or the like. The maskbody side 27 may also be referred to as the mask user side 27,indicating the portion of the mask body 12 that faces towards the faceof a user when the filter mask is worn by the user. Substrate 174 mayprovide added rigidity to the sealing member 26. Alternately, asexemplified in FIGS. 72-85, the substrate 174 may act as the sealingmember 26. For example, the substrate 174 may be flexible such that thesubstrate 174 provides a seal against the face of a user. In someembodiments, the sealing member 26 may include a resilient member. Forexample, the sealing member 26 may be resilient such that when a userwears the mask 10, the resilient sealing member 26 resists deformationagainst the face of the user, thereby forming a seal between the mask 10and the face of the user. It will be appreciated that the flexiblesubstrate 174 may also have a sealing member 26 to improve the sealbetween the mask body and the face of the user. It will also beappreciated that a soft material may be provided to the substrate 174 toimprove the comfort of the user without affecting the seal.

It will be appreciated that strap attachments 90 may be provided on theclosed cell foam itself, substrate 174 (as exemplified) or both theclosed cell foam and substrate 174.

Substrate 174 may be made of a variety of materials. For example,substrate 174 may be made of fiberglass, wood, compressed cellulose,plastic or metal. If substrate 174 is made of plastic, it may be made byinjection molding or other thermoplastic forming process such asrotational molding, compression molding, vacuum forming or pressureforming. According to this embodiment, as substrate 174 has a sealingmember 26 applied thereto, substrate 174 may be easily mass producedusing forming processes which provide formed products having morevariance. Alternately, or in addition, substrate 174 may be made ofmetal, e.g., aluminum, copper, copper coated steel, copper coatedaluminum or the like. An advantage of this design is that stampingplants may be easily converted to produce substrates by providing analternate stamping form. Accordingly, a stamping plant may be quicklyretooled to produce a filter mask.

Optionally, substrate 174 may provide a biasing action to compress asealing member 26 against the face of a user. Accordingly, asexemplified in FIGS. 64 and 83, substrate 174 comprises a filterattachment portion 176 and a flange portion. Juncture 178 is providedbetween flange portion 88 and filter attachment portion 176. Juncture178 may provide a biasing force. For example, juncture 178 may beflexible section of substrate 174, which is formed as a spring member.Accordingly, for example, juncture 178 may be accordion shaped orcorrugated. When filter mask 10 is placed on the face of a user, flangeportion 88 maybe deflected away from the face of a user by interactionbetween the face of a user and flange portion 88. In such a case,juncture 178 may be sufficiently flexible to permit flange portion 88 tomove away from the face of the user so that the filter mask seatscomfortably on the face of a user while still applying an inward forceto maintain contact between sealing member 26 and the face of a user.

In some embodiments, at least a portion of the mask body 12 may bepartially see-through and/or transparent to allow a portion of theuser's face to be seen. Providing a transparent portion of the mask body12 may increase the ease of communication with others while the user iswearing the mask 10. For example, as exemplified in FIGS. 101-104, themask body 12 includes a transparent portion 13. As exemplified in FIGS.103-104, the transparent portion 13 allows the face of the user to beseen more clearly. As shown, the mouth and nose may more clearly be seenthrough the transparent portion 13. It will be appreciated that, in someembodiments, the entire mask body 12 may be at least partiallysee-through. For example, as exemplified in FIGS. 105-120, the entiremask body 12 is transparent.

Accordingly, when the mask body 12 includes the transparent portion 13,the filter assembly 14 may be positioned below the mouth of the user inorder to provide visual access to the user's mouth and/or nose.

In some embodiments, the mask 10 may include a removable insert 11, asexemplified in FIGS. 139-140. As illustrated in FIG. 139, the insert 11may be positioned within the mask body 12 to cover some or all of thetransparent portion 13. Accordingly, when the insert 11 is positionedwithin the mask body 12, the transparent portion 13 is at leastpartially covered, or optionally fully covered. When the transparentportion 13 is covered by the insert 11, the nose and mouth region of theuser may be hidden from view.

Face Sealing Member

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, in order to reduce ambientair leaking into the volume 28, a sealing member 26 may be provided. Thesealing member may be any sealing member known in the mask arts. Forexample, the sealing member 26 may be a gasket, silicon, rubber, an opencell foam, a closed cell foam, an inflatable member or the like. Thesealing member may be provided on the entire perimeter of the face plate20 or the mask body 12.

In some cases, a person, e.g., a patient or a doctor or a nurse, maywear glasses. In such a case, a sealing member 26 may be constructed soas to deform around the temples of a pair of glasses. Accordingly, thesealing member may have a sufficient depth (between the mask body 12 andthe face of a user) so as to deform around and form a seal around thetemple of the eyeglasses. See for example FIG. 18 wherein the temple 96of the pair of eyeglasses 94 of FIG. 17 is positioned against thesealing member 26 and the sealing member has deformed to extend aroundtemple 96. It will be appreciated that, in some embodiments, only theportion of the sealing member that is located at a position that wouldengage the temples 96 of eyeglasses 94 may be sealable about thetemples.

Alternately, or in addition, as exemplified in FIG. 17, the temples 96of eye glasses 94 may have an annular sealing member positioned on thetemples 96 (e.g., slideably positionable) so as to be positioned betweenthe face of a person and the filter mask 10 when the person is wearingthe filter mask.

In some embodiments, eyeglasses 94 may be worn externally to the mask10, without affecting the performance of the mask 10. For example, if asexemplified in FIGS. 110-115, the mask body 12 only seals the mouth andnose of a user, then the mask body 12 may include one or more externalrecesses for supporting eyeglasses 94. In some embodiments, thesubstrate 174 may include a recess 95 on either side of the user's nosefor receiving eyeglasses 94. The recesses may provide stability andsupport for the eyeglasses 94 to be worn outside the mask 10 on theuser. Accordingly, in the example embodiment of FIGS. 110-115, theglasses may be located behind face plate 20. In some embodiments, thesealing member 26 may include the recesses for receiving the user'seyeglasses 94. It will be appreciated that the recesses for eyeglasses94 may be located on and/or in any location on the mask 10.

In some embodiments, a stiffer foam may be used, e.g., a closed cellfoam, which may have a stiffness of 10-80 or 35-50 on shore 00 scale. Insuch a case, if all of a user side 25 of sealing member 26 abuts theface of a user, then sealing member 26 may not sufficiently compress toprovide a complete seal around the perimeter of sealing member 26.Accordingly, in accordance with some embodiments, the user side 25 ofsealing member 26 may be configured such that only a portion of the userside 25, e.g., the inner perimeter) contacts the face of a user. Asexemplified in FIGS. 57, 64, 125, 137, and 138A, user side 25 may havean inner perimeter 25 a and an outer perimeter 25 b with an optionalmedial portion 25 c therebetween. The inner perimeter 25 a, outerperimeter 25 b, and medial portion 25 c may also be referred to as theinner edge 25 a, the outer edge 25 b, and the width 25 c respectively.User side 25 may be shaped such that only inner perimeter 25 a oressentially only inner perimeter 25 a contacts the face of a user. Forexample, as exemplified in FIG. 64, user side may extend at an acuteangle A such that outer perimeter 25 b and optionally some or all ofmedial portion 25 c are spaced from the face of a user. Accordingly, thecontact between user side 25 and the face of a user is limited to anarrow band of user side 25 of sealing member 26. This will increase thepressure per square inch exerted on the portion of the sealing member 26that contacts the face of a user. Once the inner perimeter compresses,then more of the user side 25 may seat against the face of a user untilthe compressive force is spread across an amount of the user side 25such that sealing member will no longer compress.

It will be appreciated that other portions of the user side 25 mayprovide the contact with the face of a user, depending upon theconfiguration of user side 25. For example, outer portion 25 b mayprovide the contact portion if user side commencing at outer portion 25b extends outwardly away from the face of the user at a rate greaterthan the curvature of the face. Alternately, medial portion 25 c mayextend inwardly away from substrate 174 to form a central contactportion that abuts the face of a user (e.g., user side 25 may be convexwith medial portion 25 c the portion located the furthest outward fromsubstrate 174).

As described previously, the sealing member 26 may form a closed volume15 covering the mouth and nose of the user. The seal formed against theface of the user, thereby defining the closed volume 15, may be referredto as the closed volume perimeter. In some embodiments, at least aportion of the sealing member 26 may extend inwardly of the closedvolume perimeter into the closed volume 15, as exemplified in FIGS.53-66, 86-97, 101-117, 123-127,132, and 137-140. Accordingly, in someembodiments, the inner perimeter 25 a of the user side 25 of the sealingmember 26 may be located within the closed volume 15. It will beappreciated that the portion of the sealing member 26 located within theclosed volume 15 may vary. For example, in some embodiments, 5%,optionally 10%, optionally 15%, or optionally 20% of the width 25 c ofthe user side 25 of the sealing member 26 may be located within theclosed volume 15.

It will be appreciated that the thickness of the sealing member 26 mayvary. For example, in some embodiments, the thickness of the sealingmember 26 may be greater than 1.5″, optionally 0.25″ to 1.5″, optionally0.250″ to 1″, or optionally 0.375″ to 0.75″. In some embodiments, thethickness of the sealing member 26 may vary at different locations onthe mask 10. For example, approximately 65% of the surface area of theface sealing member may have a thickness of 0.175″ to 0.375″ oroptionally 0.08″ to 0.5″. Reducing the thickness of the sealing member26 may reduce the material required for the mask 10, thereby reducingthe weight and improving the comfort of the user.

In some embodiments, the sealing member 26 may have two regions 26 a and26 b, as exemplified in FIGS. 138A and 138B. The regions 26 a, 26 b maybe coloured differently to indicate the user side and the non-user side.For example, the region 26 b may be a darker colour than the region 26a. A darker coloured region 26 b may improve the aesthetics of the mask10 once it has been worn by reducing the visibility of oil and/or makeupdeposited on the sealing member 26 during use.

Alternately or in addition, the region 26 b may have a differentcompressibility than the region 26 a. For example region 26 b may be amore compressible foam than region 26 a.

Communication

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, a speaker 32, such as avibratory membrane or resonant member, may be provided in the face plate20. The speaker may enhance the ability of a doctor to hear a patientwhile the patient is wearing the filter mask 10. An advantage of avibratory membrane is that the speaker 32 does not permit air to passtherethrough when a person is speaking.

In an alternate embodiment, the entire face plate 20 itself may be thevibratory membrane or resonant member.

Microphone

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the mask 10 may include amicrophone 33, as exemplified in FIG. 109. The microphone 33 may be usedto receive input when a user talks while wearing the mask.

It will be appreciated the microphone 33 may be wirelessly connected byany means used in the communications arts. For example, the microphone33 may be wirelessly connected by, including but not limited to,Bluetooth, NFC, radio frequency, Wi-Fi, or any combination thereof.Accordingly, a user may connect to their mobile device and may makephone calls without taking off the mask 10 or may use their phone as aspeaker. Alternately, the microphone 33 may provide a signal to aspeaker provided on an exterior surface of the mask.

Optionally, an ear piece may be provided to allow a user to make phonecalls without removing the mask 10. In some embodiments, the microphone33 may be connected to the ear piece. It will be appreciated that themicrophone 33 may be connected to the ear piece by any means. Forexample, the microphone 33 may have a wired connection to the ear piece.The wire may extend from the microphone 33 out of the mask 10 to the earpiece worn by the user. In some embodiments, the microphone 33 may bewirelessly connected to the ear piece by, including but not limited to,Bluetooth, NFC, radio frequency, Wi-Fi, or any combination thereof. Insome embodiments, the microphone 33 may be wirelessly connectable to theear piece and have an optional wired connection to the ear piece.Accordingly, if an energy storage member in the ear piece is depleted, auser may connect the wire to the microphone 33 to allow for continueduse. It will be appreciated that each of the microphone and the earpiece may wireless connect to a cell phone.

In some embodiments, the microphone 33 may be electrically connected tothe energy storage member 136. Connecting the microphone 33 to theexisting energy storage member 136 may reduce the overall weight andcomplexity of the mask 10.

In some embodiments, the microphone 33 may be used for noise cancelling.For example, as a user breathes in and out of the mask 10, the enclosedspace may increase the noise when a user is on a phone call. Themicrophone 33 may be used to actively cancel the noise such that theuser may be heard more clearly.

In some embodiments, the mask 10 may include buttons 262 for controllingthe volume of the speaker 32 and/or microphone 33. The buttons 262 maybe located anywhere on the mask 10. Control of electrical components isdiscussed in more detail subsequently.

Emesis

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, an outlet 34 is provided incase of emesis. As exemplified in FIG. 1, the outlet 34 is provided inthe lower portion 24 of the face plate 20. As exemplified, the outlet 34comprises a port provided in a lower portion of the face plate 20 and aconduit 36 extends downwardly from the outlet 34 to a container 38.Accordingly, if a person were to vomit while wearing the filter mask,the vomit could flow downwardly due to gravity through conduit 36 andinto container 38.

In order to empty the container 38, a drain plug 40 may be provided.Container 38 may be removably attached to conduit 36 and/or conduit 36may be removable attached to mask body 12. Accordingly, if a person wereto vomit while wearing the filter mask 10, the conduit 36 and/or thecontainer 38 could be removed for cleaning and disinfection and/orreplacement.

Biological Sampling and/or Drinking

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, an openable port may beprovided. The port, when opened, enables a medical practitioner to takea biological sample from a person who is wearing the mask (e.g., fromthe mouth or nose of a person using, e.g., a swab). Alternately, or inaddition, the port enables a person wearing the mask (e.g., a medicalpractitioner or a patient) to drink while wearing the mask, such as byusing a straw. An advantage of this aspect is that a person who may beinfected need not remove the mask to enable a biological sample to betaken. A further advantage is that a person wearing the mask mayrehydrate without taking off the mask, thereby preventing a personpossibly being exposed to a virus while taking a drink, or a person whois infected spreading a virus while taking a drink.

The openable door 100 may be provided on any portion of the filter mask10, such as face plate 20, which is exemplified in FIG. 14, or thefilter assembly itself (see for example FIGS. 60-62 and 64-66). Ifopenable door 100 is provided on filter assembly 14, then an access port102 may extend optionally through one or more layers of filter media 48or between sections of the filter media. As exemplified in FIGS. 60-62and 64-66, filter assembly 14 has an outer filter housing 180 and aninner filter housing 182. Optionally, outer filter housing 180 ismoveable with respect to inner filter housing 182 so as to revealopenable door 100 or port 102 if no door 100 is provided. For example,outer filter housing 180 may be pivotally mounted to, translateablymounted to or removably attachable to inner filter housing 182 (see forexample FIG. 66). Accordingly, in such embodiments, port 102 is onlyaccessible when outer filter housing 180 has been moved to a portaccessible position. As exemplified, each of outer filter housing 180and inner filter housing 182 may have one or more filter layers providedtherein. As exemplified, outer filter housing is provided with a foamfilter 118 and inner filter housing is provided with a biological filtermaterial 116. As discussed subsequently, each of outer and inner filterhousings 180, 182 may be provided with one or more layers of a foamfilter 118, a felt filter 120 and a biological filter material 116.

It will be appreciated that, as exemplified in FIG. 64, port 102 mayextend through the filter media itself or, alternately, filter media maybe provided to either side of port 102.

The openable door 100 may be a pivotally mounted door, a door whichtranslates or a removable door. When opened, the door 100 reveals a port102 through which a medical sampling device may be inserted. Asexemplified, the medical sampling device is a swab 104 having a cottontip 106. Any medical sampling device, such as a bel bulb pipetor, may beused.

When the door 100 is open, a virus may possibly pass through port 102.Accordingly, a sealing membrane 108 or a valve, such as a duck billvalve, may be provided. As exemplified in FIG. 14, sealing membrane 108has an opening through which swab 104 extends. When swab 104 is insertedthrough port 102, sealing membrane 108 may abut against the portion ofthe face plate 20 surrounding port 102 and effectively close port 102while the biological sample is taken. After the sample is taken, theswab may be removed and door 102 moved to the closed position, therebyclosing port 102. Alternately, if a duck bill valve 184 is used, the actof insertion of, e.g., straw 186, will open the valve 184 (see forexample FIG. 66).

It will be appreciated that the sealing membrane 108 may be located at afixed position on the medical sampling device. Optionally, the sealingmembrane may be slidably mounted or mountable on a medical samplingdevice. Accordingly, the sealing membrane may be positioned on swab 104immediately rearward of cotton tip 106. As the swab is inserted throughport 102, the shaft 112 of the medical sampling device may slide througha central opening in membrane 108 thereby closing the port for a longerperiod of time as a biological sample is taken. The sealing membrane 108may be provided already mounted on the medical sampling device or thesealing membrane 108 may be placed on a shaft 112 of a medical samplingdevice prior to the biological sample being taken, e.g., prior to door100 being opened.

It will be appreciated that a sealing membrane 108 may be used with astraw to seal port 102 when a person is drinking through a straw.

It will be appreciated that a sealing member (e.g., a gasket made of,for example, silicone or rubber or other sealing material) may beprovided on the inner side of door 102 and/or the portion of face plate20 surrounding port 102 so as to seal the port 102 when the door 100 isclosed.

Alternately, instead of an openable door 100, or in addition to anopenable door 100, a penetrable membrane 110 may be provided at the port102. The penetrable membrane 100 may have an opening through which amedical sampling device may be pushed to enable a biological sample tobe taken. For example, penetrable membrane 100 may have a small openingthat is enlarged when a medical sampling device is inserted therethroughor it may comprise one or more overlapping flaps (such as an openableiris) which are deformed or moved when contacted by a medical samplingdevice to enable the medical sampling device to pass therethrough. Anadvantage of this design is that the port 102 is closed until themedical sampling device is inserted.

General Description of a Filter Assembly

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, as exemplified in FIGS. 1,5, 13, 15, 20, 53, 72, 87 and 110 one or more filter assemblies 14 maybe in air flow communication with volume 28 and positioned spaced fromthe mouth of a person. An advantage of this design is that, if a personwere to vomit while wearing the filter mask 10, the air treatment memberwould not be soiled by the vomit.

Optionally, as exemplified in FIGS. 1, 5, 13 and 20, the filter assemblyis positioned above the face plate 20, and optionally above the maskbody 12, so as not to obstruct the view of the face of a person wearingthe mask. Accordingly, the filter assembly 14 may be positioned above aperson's head (see, e.g., FIG. 1) or above the face plate 20 (see, e.g.,FIGS. 5, 13, 15 and 27). Alternately, the filter assembly 14 may bepositioned below the mouth of the user as exemplified in FIGS. 101-117.

As exemplified in FIGS. 1, 12, 15 and 28, the filter assembly 14 may bein air flow communication with the volume 28 by one or more conduits 42.One or more air flow ports 44 may be provided in the upper portion 22 ofthe face plate 20, side panel 18 or the mask body 12. As exemplified inFIGS. 1 and 15, conduit 42 extends upwardly and rearwardly from the airflow port 44 to the filter assembly 14 or, as optionally exemplified inFIG. 27, upwardly. As exemplified in FIGS. 5, 12 and 27, the filterassembly may be provided (e.g., mounted to) the side panel 18 of themask body 12 such that the air flow conduit 42 is a passage that extendsupwardly from side panel 18 to the interior of the filter assembly 14.

It will be appreciated that, in some embodiments, the one or moreconduits 42 may not provide airflow into the volume 28. Instead, asexemplified in FIG. 116, upon inhalation, air may exit the filterassembly (fan 130) and travel directly into the volume 28. Alternately,as exemplified in FIG. 83, upon inhalation, air may pass through amounting assembly 210 that may function as a conduit 42.

The filter assembly comprises one or more air treatment members 46 tofilter air that enters the filter assembly 14. The air treatment member46 may comprise one or more filters that remove biological material froman air flow stream travelling through the filter assembly 14. Forexample, as exemplified in FIGS. 2, 11, 12 and 32-27 and as discussedsubsequently, the air treatment member 46 may be one or more filtermedia 48 so as to provide a layered or multi-layer filter. Asexemplified in FIGS. 3 and 4, the air treatment member may be anelectrostatic precipitator 50, which may be provided, in a tortuous path52. It will be appreciated that a combination of a filter media 48 andan electrostatic precipitator 50 may be used. It will also beappreciated that other air treatment members, such as a cyclone, may beused.

Removable Filter Assembly

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, as with container 38, one ormore filter assembles 14 may be removably attached to mask body 12, suchas by being removably attachable to conduit 42 (or mounting assembly 210that functions as a conduit 42) and/or conduit 42 may be removableattached to mask body 12.

One advantage of this design is that, if the filter assembly weredamaged or the air treatment member 46 needed to be changed, the conduit42 and/or the filter assembly 14 could be removed for cleaning anddisinfection and/or replacement.

Another advantage is that the mask body 12 may have different filterassemblies mountable thereto. For example, filter assemblies 14 havingdiffering levels of filtration may be provided, each of which ismountable to the same mask body 12.

Alternately, or in addition, filter assemblies 14 having differing lifespans of the filter material may be provided, each of which is mountableto the same mask body 12, thereby enabling the mask body 12 to be auniversal mask body 12. For example, one filter assembly useable for,e.g., 12, 24 or 36 hours may be provided. Such a filter assembly may beprovided for a patient who visits a doctor or a hospital. The user willwear the mask for a short period of time and therefore, less filtermaterial may be used. Another filter assembly may be useable for alonger period of time (e.g., a week, two weeks, a month or longer). Sucha filter assembly may be used for medical practitioners. An advantage ofthis design is that, if filter material capable of blocking the flow ofa virus is in limited supply (e.g., HEPA, ULPA, MERV 15, MERV 16, MERV17or higher filter material), then the amount of filter material that isused in a filter assembly may be selected based on the length of timethat the filter assembly will be in use.

Accordingly, a universal mask body 12 may have different filterassemblies mountable thereto. When a mask is required, a universal maskbody that has a suitable filter assembly 14 mounted or removably mountedthereto, based on the length of time that the filter mask 10 is expectedto be in use, may be provided. Similarly, mask bodies of differing sizes(e.g., sized fora child, a small adult or a large adult), may use thesame filter assemblies 14.

It will be appreciated that, after a filter mask 10 has been used, thatthe filter assembly 14 may be removed from the mask body 12. Asdiscussed subsequently with reference to FIGS. 121-122, the mask body12, which may have no filter media attached thereto, may then besanitized (disinfected) so that the mask body 12 may then be used for adifferent person.

Alternately, or in addition, filter assemblies having different sizesand/or configurations may be used with a single mask body 12 therebyenabling the mask body 12 to be a universal mask body 12. An advantageof this design is that, if filter material capable of blocking the flowof a virus is in limited supply (e.g., HEPA, ULPA, MERV 15, MERV 16,MERV17 or higher filter material), then a filter assembly may bedesigned which provides a desired level of filtration with the availablefilter material. Based on the filter material that is available, thesize and/or shape of the filter assembly may be varied. However, anysuch filter assembly may be mateable with one or more ports 44 providedon a mask body 12. It will be appreciated that if not all ports 44 areattached in air flow communication with a filter assembly, then theunused ports 44 may be blocked by, e.g., a stopper, a valve or the like.

Optionally, as exemplified in FIGS. 13, 15 and 16, a mask body 12 mayhave two filter assemblies 14 attached thereto. One advantage of thisdesign is that a first filter assembly 14 may be used while the secondfilter assembly 14′ is reserved as a backup. Accordingly, referring toFIG. 13, filter assembly 14 may be used while filter assembly 14′ isreserved. Air flow conduit 42 may be closed such as by a valve (notshown). If filter assembly 14 is damaged or if filter assembly 14 hasreached the end of the filter life, then filter assembly 14′ may beplaced in air flow communication with the mask body 12 by, e.g., openinga valve. It will be appreciated that filter assembly 14 may be isolatedfrom air flow communication with the mask body 12 by, e.g., closing avalve. Another option for opening and closing air flow communicationwith the mask body 12 may be to cover of close the inlet and outlet port56 of a filter assembly 14, 14′.

As exemplified in the embodiment of FIGS. 15 and 16, a valve 114 such asa ball valve, may be opened or closed by rotating air flow conduit 42.In FIG. 16, air flow conduit 42′ has been rotated about 90° therebyclosing valve 114′. Accordingly filter assembly 14′ has been removedwhile mask body 12 remains closed to air flow through conduit 42′.Therefore, a filter assembly 14 may be replaced by a new or a cleanedfilter assembly while the ports 44 with which the filter assembly is inair flow communication when positioned on the mask body 12 are closed.

It will be appreciated that the valve 114 or other closure member may belocated at different locations, such as the inlet of air flow conduit 42distal to mask body 12. Accordingly, the inlet of air flow conduit 42distal to mask body 12 may be closed or automatically closed when afilter assembly 14 is removed. For example, the filter assembly may pushopen a flap that rotates inwardly into conduit 42 when the filterassembly is attached to conduit 42. The flap may be biased to close theinlet of air flow conduit 42 distal to mask body 12 when the filterassembly is removed.

It will be appreciated that, in an alternate embodiment, filter assembly14 may be secured in position to mask body 12, such as by an adhesivewhich may be applied, e.g., between filter assembly 14 and mask body 12as exemplified in FIG. 25 or to the interior of mask body 12, e.g., tosecure conduits 42 to ports 44 as exemplified in FIG. 26.

In some embodiments, the filter assembly 14 may be rotatably mounted tothe mask body 12. Accordingly, as exemplified in FIGS. 58 and 59, maskbody 12 may have screw threads 188 and filter assembly (e.g., innerfilter housing 182) may have mating screw threads 190. Alternately, asexemplified in FIGS. 83 and 90, a bayonet mount may be used, optionallyas part of a mounting assembly 210.

As exemplified, the mounting assembly 210 may include a first mountingmember provided on the filter assembly 14 and a second mounting memberprovided on the mask body 12. For example, the bayonet mount 210, asexemplified in FIGS. 72-97, may include a male portion 212 having aplurality of radial pins 214 and a female portion 220 having a pluralityof radial seats 222. As exemplified, the male portion 212 is located onthe filter assembly 14 and the female portion 220 is located on thesubstrate 174. It will be appreciated that the male portion 212 may belocated on the substrate 174 and the female portion 220 may be locatedon the filter assembly 14. As exemplified, the first and second mountingmembers of the mounting assembly 210 may define a portion of the airflow passage of the filter assembly 14, as exemplified in FIGS. 72-97.

During use, the male portion 212 is inserted into the female portion 220such that the plurality of radial pins 214 are passed through gapsbetween the plurality of radial seats 222. Once the plurality of radialpins 214 are inserted past the radial seats 222, the filter assembly 14may be rotated such that the plurality of radial pins 214 are seatedbehind the plurality of radial seats 222, thereby securing the filterassembly 14 to the substrate 174.

In some embodiments, as exemplified in FIGS. 72-97, the bayonet mount210 may include a mount seal 216. The mount seal 216 may be positionedbetween the male portion 212 and the female portion 220 such that theseal 216 is compressed between them. The seal 216 may improve leakage ofthe filter mask 10, improving the safety of the user.

Downwardly Facing Filter Inlet

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, as exemplified in FIG. 1,the filter assembly 14, which may comprise a filter housing 54 (whichmay be referred to as a filter body 54) having an inlet and outlet port56 that faces downwardly. An advantage of the inlet and outlet port 56facing downwardly is that rain would be inhibited from entering into theinlet and outlet port 56. The inlet and outlet port 56 may optionallyface the top of a head of a person wearing the filter mask 10 (see forexample FIG. 1) or the ground (see for example FIG. 88). It will beappreciated that the filter assembly may optionally function as a filterhousing and the filter media may be mounted to the filter assembly 14.Alternately, the filter assembly may receive a filter housing 54 whereinthe filter media by itself or as part of a filter cartridge 194 may bemounted to the filter housing 54.

Optionally, as exemplified in FIG. 1, a descending lip 58 may beprovided. The descending lip 58 extends generally downwardly so as toinhibit air travelling laterally into the inlet and outlet port 56.Accordingly, if it were raining, rain would tend to drip off the filterhousing 54 and not be drawn into the inlet and outlet port 56. Thedescending lip 58 may extend downwardly any desired amount from theouter surface 60 of the filter media 48 (see FIG. 2) or the inlet andoutlet port 56 of the electrostatic precipitator 50 (see FIGS. 3 and 4).

Filter housing 54 may be of any particular shape and size provided itmay house suitable air treatment member or members 46. Accordingly,filter housing 54 may be a generally rectangular member, which is in airflow communication with air flow conduit 42.

As exemplified, filter housing 54 may be provided with an air flowpassage, such as an upper air flow passage 62. As exemplified in FIGS. 1and 2, if the air treatment member 46 is a filter media 48, then theentire upper surface 64 of the filter media 48 may be exposed to the airflow passage 62 and may comprise the lower surface of the air flowpassage 62.

Air flow passage 62 may be of any configuration that enable a suitableair flow to travel therethrough. As exemplified in FIG. 2, air flowpassage 62 has upper and lower sides 68 and 70. In the embodiment ofFIG. 2, lower side 70 may be porous and provide a surface against whichfilter media 48 seats when installed in the filter housing 54.Alternately, it may be an opening in the lower wall of the passage 62.

Air flow passage 62 may be provided with ribs 66. Ribs 66 may reinforcethe upper surface 68 of the filter housing 54. Alternately, or inaddition, ribs 66 may provide a standoff to limit the extent to whichfilter media 48 may be inserted into filter housing 54, e.g., if thelower side of passage 62 is opening in the lower wall of the passage 62.

As exemplified in FIG. 2, filter housing 54 has a cavity 158 (defined bythe lower side 70 of passage 62 and sidewalls 72 of filter housing 54)in which filter media 48 is positioned. Filter media may be removablypositionable in the cavity 158 through an entrance to the cavity 158,also referred to as a port. Accordingly, the filter media 48 may beremoved for cleaning and disinfection and/or replacement.

Layered Filter Media

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, one or more filter media 48may be provided in cavity 158 of the filter housing 54. The filter media48 may be any porous filter media. Optionally, the filter mediacomprises at least one layer of filter media that is selected to preventor limit the flow therethrough of biological material. Accordingly, itmay have pore sizes that inhibit or prevent the flow therethrough ofbacteria and/or viruses. Examples of suitable filter material includeHEPA, ULPA, MERV 15, MERV 16, MERV17 or higher filter materials.Optionally, the filter media may be a pleated filter media (see forexample, FIG. 42). Such filter material may be referred to as biologicalfilter media 116.

Optionally, according to this aspect, one or more other filter materialis provided on one or both sides of the biological filter media. Duringuse, the efficacy or life span of the biological filter media may bedegraded by moisture in the air (e.g., rain) or particulate contaminantsin the air that is inhaled. Providing more porous filter media that isselected to filter such material on the upstream side of the biologicalfilter media when a person inhales may extend the life span of thebiological filter media. Similarly, during use, when a person exhales,droplets in the exhalation of a person may contaminate the biologicalfilter media. Providing more porous filter media that is selected tofilter such material on the upstream side of the biological filter mediawhen a person exhales may extend the life span of the biological filtermedia. Optionally, such more porous filter media may be provided on eachside of the biological filter media.

As exemplified in FIG. 11, the filter media 48 may comprise a foamfilter 118 (open or closed cell foam) on each side of biological filtermedia 116. As exemplified in FIG. 12, the filter media 48 may comprise afoam filter 118 (open or closed cell foam) and an inner felt filter 120on each side of biological filter media 116. The foam and felt filtersprotect the biological filter media 116 by inhibiting moisture dropletsand particulate contaminants passing therethrough to the biologicalfilter media 116. In other words, the foam and felt filters may protectthe biological filter media 116 by capturing larger debris and/ordroplets, thereby increasing the lifetime of the biological filter media116.

It will be appreciated that various different combinations of layeredfilters, with and without a fan 130 to assist inhalation and/orexhalation (as discussed subsequently) may be provided. For example,FIGS. 30 and 31 exemplify an embodiment in which a single foam filter118 is provided on top of a single HEPA filter 116.

FIG. 32 exemplifies an embodiment wherein a fan 130 is provided forassistance with inhalation. Accordingly, filter housing 54 has aninhalation side 146 and an exhalation side 148. Filter housing 54 may beconfigured, as exemplified in FIG. 32, such that inhalation andexhalation sides 146, 148 are provided on opposed lateral sides offilter housing 54. Alternately, it will be appreciated that inhalationand exhalation sides 146, 148 may be positioned with one forward of theother. As separate inhalation and exhalation sides 146, 148 areprovided, exhalation side 148 is provided with one or more exhalationports 150 and inhalation side 146 is provided with one or moreinhalation ports 152 (see, e.g., FIG. 34). Inhalation ports 150 may belocated at any location on inhalation side 146 and exhalation ports 152may be provided at any location on exhalation side 148. The inhalationand exhalation ports 150, 152 may be provided on the same side of filterhousing 54 or different sides, and optionally each may face downwardlyas discussed previously. As exemplified in FIG. 32, exhalation ports 150may be provided on a rear side of exhalation side 148 of filter body. Inthis embodiment, not shown, inhalation ports 152 may be provided, e.g.,on a front side of inhalation side 146 of filter housing 54.Alternately, as exemplified in FIG. 34, inhalation ports 152 may beprovided on a rear side of inhalation side 146 of filter body. In thisembodiment, not shown, exhalation ports 150 may be provided, e.g., on afront side of exhalation side 148 of filter housing 54.

In the embodiment of FIG. 32, on inhalation side 146, a foam filter 118and an underlying HEPA filter 116 are provided on the intake side of fan130. A foam filter 118 is provided on the lower outlet end of fan 130. AHEPA filter 116 is provided across the entire air flow passage,accordingly extending across both inhalation and exhalation sides 146,148 of filter housing 54. A foam filter 118 is provided on the lower(volume 28 side) of the HEPA filter 116. A foam filter 118 is providedon the upper side of the exhalation side 148 of HEPA filter 116.

FIG. 33 exemplifies an embodiment similar to that of FIG. 32 except thatin the embodiment of FIG. 33, only a foam filter 118 is provided on theintake side of fan 130.

FIG. 35 exemplifies an embodiment similar to that of FIG. 33 except thatin the embodiment of FIG. 35, inhalation ports 152 are positionedsimilarly to those of the embodiment of FIG. 34. Accordingly, inletports 152 of inhalation side 146 are provided in a rear side of theinhalation portion 146 and the exhalation ports 150 are provided, e.g.,on a front side of the filter housing 54.

FIG. 36 exemplifies an embodiment wherein filter housing 54 does notinclude a common air flow passage for inhalation and exhalation. In thisembodiment, inhalation side 146 has a foam filter 118 and a HEPA filter116 on the intake side of fan 130 and a HEPA filter 116 on thedownstream side of fan 130. On exhalation side 148, a foam filter 118 isprovided upstream of HEPA filter 116.

FIG. 37 exemplifies an embodiment that is similar to the embodiment ofFIG. 36 except that two fans 130 are provided on inhalation side 146 andthe second (downstream) fan 130 is provided downstream of the HEPAfilter 116 that is positioned downstream of the first (upstream fan)130.

In the preceding examples, it will be appreciated that foam filter 118may be any more porous media (any one or more layers of more porousfilter media) that is provided on an upstream and/or downstream of abiological filter media 116. Similarly, it will be appreciated that HEPAfilter 116 may be any one or more layers of a biological filter media116. It will also be appreciated that the orientation of the layeredfilters may vary depending on the mask body design. For example, FIGS.72-97 exemplify an embodiment in which a single foam filter 118 isprovided below a single HEPA filter 116. As exemplified in FIGS. 98-100,a single foam filter 118 is provided below each HEPA filter 116. Asexemplified in FIGS. 101-120, a single biological filter media 116 isprovided in the filter housing 54. As exemplified, in such embodimentsthe air inlet and air outlet may face downwardly when the mask is wornby a user.

The foam filter material may have 100 pores per inch or more (e.g., thepores may have a size of about 150 microns). For example, the foam mayhave 500 or 1,000 pores per inch (e.g., pores about 15 microns in size).The pores per inch of the foam may be increased, e.g., by heatcompressing the foam.

Optionally, the foam is a reticulated foam, such as a reticulatedpolyurethane foam.

When a person is wearing the filter mask 10 and inhales, air enters theinlet and outlet port 56 or separate inlet ports 150, travels throughthe air treatment member 46 and through the air flow conduit 42 into thevolume 28 thereby enabling the person wearing the filter mask 10 tobreath in filtered or treated air. When a person is wearing the filtermask 10 and exhales, air enters the volume 28 and optionally passesthrough the air flow conduit 42, the air treatment member 46 and outthrough the inlet and outlet port 56 or separate outlet ports 152. Itwill be appreciated that, in an alternate embodiment, a separate outletport may be provided elsewhere, such as in face plate 20, air flowconduit 42 or the filter housing 54 such that exhaled air does not haveto pass through the air treatment member 46.

Replaceable Filter Media and Filter Assembly Construction

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, filter assembly 14 may beopenable to replace one or more filter media provided therein (which maybe mounted in a filter housing 54 or a filter cartridge 194) or may havea cavity in which, e.g., one or more filter layers or a filter cartridge194 or a filter housing 54 is insertable therein.

Alternately, or in addition, in accordance with this aspect, which maybe used by itself or in combination with one or more other aspects, oneor more filter members may be secured in a filter holder on an exteriorof the filter holder (see for example FIG. 81) or may be positionable isan openable filter cartridge 194 as discussed subsequently (see forexample FIG. 119). An advantage of this aspect is that the filter membermay be more readily secured in position. A further advantage is that thesealing of the filter member to the filter holder is more visible andthe seal may be readily checked to determine of the seal is complete.

These aspects may be used if the filter assembly is removably mounted tothe mask body or if the filter assembly is secured (non-removablymounted) to the mask body.

In accordance with this aspect, some or all of the filter media 48 maybe removably positionable in the filter housing 54. For example, thefilter media may be compressible (e.g., foam) which may be secured inposition in cavity 158 by compression. Alternately, filter media 48 mayhave one or more rigid walls (e.g., in the case of a pleated filter)that enables the air treatment member 46 to be held in position by afriction fit (see for example FIG. 119). Alternately or in addition, amechanical locking member may be provided that engages with the airtreatment member 46 so as to inhibit the removal of the air treatmentmember 46. Alternately, the air treatment member 46 may be slidablyinsertable through an openable door provided in a sidewall 72 and/or anopenable bottom and/or an openable top and/or lid 154 (see for exampleFIG. 49). The opening providing an entrance to the cavity 158 may alsobe referred to as a port and the port need not be openable.

In some embodiments, the cavity 158 may have an insertion direction forthe filter media 48. When the filter media 48 is positioned within thecavity 158, the filter media 48 may be recessed inwardly of the port (orentrance to the cavity 158) in the insertion direction. A portion of thecavity 158 walls may define a descending lip 58, which may extendoutwardly of the filter media 48 in a direction that is opposite to theinsertion direction. In other words, the filter media 48 may be recessedwithin the cavity 158 such that there is a portion of the walls definingthe cavity 158 that does not contain the filter media 48. Thisdescending lip may provide additional protection to the filter media 48by providing a protective ridge. Additionally, the descending lip mayprovide a surface for attaching other components to the mask 10 withoutinterfering with the filter media 48.

In some embodiments, the cavity 158 may have a header 117 located on thedownstream side of the cavity 158 (relative to inhalation by the user),as exemplified in FIG. 83. The header 117 may be positioned between thefilter media 48 and the top and/or lid 154 of the filter housing 54. Theheader 117 may be used to assist with maintain sufficient airflow in thefilter housing 54.

Optionally, the more porous filter media is removable (e.g., the foam118 and/or the felt 120 filter media). Therefore, the more porous filtermedia may be removed for cleaning and reuse or replaced by clean moreporous filter media. An advantage of this design is that the life spanof the biological filter media 116 may be extended.

Optionally, biological filter media 116 may be non-removably secured inposition, such as by securing the biological filter media 116 to filterhousing 54. An advantage of this design is that the edges of thebiological filter media 116 may be secured to the filter housing 54 by,e.g., an adhesive (e.g., hot melt glue, silicone, etc.) welding or thelike, to inhibit or prevent bypass of the biological filter media 116.

Optionally, the filter media is at least partially secured to an outersurface of the filter housing 54 and/or a portion of cavity 158 offilter body that is easily visible. An advantage of this design is thatthe seal of the biological filter material 116 to the filter body isvisible and may enable a reliable and quick quality control visualinspection of a filter body having biological filter material 116secured in position to confirm that the biological filter material 116is secured such that bypass of the biological filter material 116 willnot occur during use of filter assembly 14.

FIGS. 42-52 exemplify a method of securing a filter media (optionally abiological filter media 116) in a filter housing 54. As exemplified inFIG. 42, biological filter material is positioned to be slid into filterhousing 54 via opening 160 in sidewall 72 of filter housing 54. Opening160 may be of any configuration. As shown in FIG. 42, the opening is ina zig-zag shape to enable a biological filter material 116 that isfolded in an accordion pattern to be slid into filter housing 54. Itwill be appreciated that opening 160 may be provided in any wall offilter housing 54.

Optionally, as exemplified in FIG. 42, an opposed wall of filter housing54 may have an opening 160 so as to enable one end of biological filtermaterial to be slid through cavity 158 (see FIG. 43) to the opposed walland out opening 160 in the opposed wall of filter housing 54 such that,as exemplified in FIG. 44, an end of biological filter material 116extends outwardly on each opposed side 72 of filter housing 54.

Once biological filter material 116 is positioned in filter housing 54,biological filter material 116 may be secured to the filter body. Asexemplified in FIG. 45, adhesive 162 may be applied to the exterior offilter body at the location at which biological filter material 116extends through opening 160 in sidewall 72. Adhesive 162 may be providedto the upper surface and/or the lower surface of biological filtermaterial 116. Optionally, as exemplified in FIG. 46, an adhesive 162 mayalso be applied in cavity 158 at the location at which biological filtermaterial 116 abuts longitudinally extending sidewall 166 of filter body.Accordingly, all portions of biological filter material which engage awall of filter housing 54 are secured to the filter body with thesealing means readily visible.

Subsequent to optionally applying an adhesive interior of cavity 158, asexemplified in FIG. 47 one or more layers of more porous filter mediamay be placed in filter housing 54 above biological filter material 116so as to rest above biological filter material 116 (see, e.g., FIG. 48)or below biological filter material 116 (see, e.g., FIG. 83).

A lid 154 may then be placed on the filter housing 54 (see, e.g., FIG.49). Lid 154 may be secured in position by any manner, such as amechanical lock or, as exemplified in FIG. 50, by one or more straps156. Optionally, straps 156 are stretchable (e.g., elastomeric) so as toenable straps 156 to be expanded and slid into position. Any number ofstraps 156 may be used.

It will be appreciated that if one or more layers of more porous filtermedia are positioned below biological filter material 116, that thesemay also be removable. In such an embodiment, the bottom of filterhousing 54 may be openable, optionally in a similar manner to lid 154.Alternately, or in addition, the one or more layers of more porousfilter material may form an interference fit with the filter housing 54such that a lid is not required (see e.g., FIG. 83). In such anembodiment, the more porous filter media 116 may be removed by pullingon the filter 116 such that the friction between the filter 116 and thefilter housing 54 is overcome. It will be appreciated that, such as inthe embodiment of FIG. 83, a lid may not be provided.

It will be appreciated that the filter material that is secured inposition may be any filter material. Further, one or more layers offilter material may be secured in position.

FIGS. 67-71 exemplify an alternate embodiment for securing a filtermember 46 in a filter mask 10. As exemplified, in FIG. 69, biologicalfilter material 116 is positioned in openings 160 (see FIG. 67) of twolaterally opposed side panels 192. Accordingly, a side panel may beprovided on each laterally opposed side of biological filter material116. Adhesive 162 may then be applied on the outer side of each panel192 to secure biological filter material 116 in each side panel 192 (seeFIG. 68) and form a filter cartridge 194. As discussed previously,applying adhesive 162 on the outer side of side panels 192 enables aquick visual inspection that a full seal has been provide betweenbiological filter material 116 and side panel 192. The assembled filtercartridge may then be slid into a recess in a filter assembly 14 or afilter housing 54. As exemplified in FIGS. 70 and 71, filter assembly 14comprises a filter body that is formed as part of mask body 12 and has afront cavity 158 in which the assembled filter cartridge 194 isslideably receivable.

FIGS. 72-120 exemplify additional embodiments wherein, the filtercartridge 194 may include one or more filters, which may be removablyreceivable in the filter assembly 14 of the filter mask 10 by itself oras part of a filter housing 54. As exemplified in, FIGS. 72-100, thefilter cartridge 194 includes a foam filter 118 and a biological filter116. As exemplified in FIGS. 101-120, the filter cartridge 194 includesa biological filter 116 and the filter cartridge 194 is receivable inthe filter housing 54.

As illustrated in FIGS. 77-120, the filter cartridge 194 may be removedfrom the filter assembly 14. It will be appreciated that the filtercartridge 194 may be removable when the filter mask 10 is secured inplace on the user's face, or when the filter mask 10 has been removedfrom the user's face. An advantage of the cartridge 194 being removablewhile the filter mask 10 is secured to the user's face is that the userdoes not need to expose themselves to the atmosphere to change thefilter cartridge 194. Reducing exposure to the user's environment mayimprove the safety of the user when the user is in a high-riskenvironment. The cartridge 194 may be easily removed and replaced with anew cartridge 194 without ever requiring the user to expose themselvesto their environment. Alternately, or in addition, foam filter 118 maybe removed while the biological filter 116 remains in place andoptionally the filter cartridge remains in place is the filter assembly.

It will be appreciated that the filter cartridge 194 may be secured tothe filter assembly 14 by any means known in the art, including, but notlimited to, magnets, suction, mechanical fasteners, mechanical locks,friction fits, etc.

As exemplified in FIGS. 72-100, and more clearly shown in FIG. 83, thefilter cartridge 194 may include a mechanical locking mechanism. Thelocking mechanism may include first and second engagement members whichmate to secure the filter cartridge 194 in position. For example, asexemplified, the filter cartridge 194 has a protrusion 196 that isremovably receivable in a corresponding recess 198 on the filterassembly 14. The filter assembly 14 may include a ramp and/or guide 200for guiding the filter cartridge 194 into the filter assembly 14. Duringinstallation, the filter cartridge 194 may be slid into the filterassembly 14, sliding the protrusion 196 along the guide 200 and into therecess 198. In some embodiments, the filter assembly 14 may be openable.For example, as exemplified in FIGS. 72-100, the portion of the filterassembly 14 that contains the recess 198 may be flexible to allow thecartridge 194 to be more easily inserted into and/or removed from thefilter assembly 14. In some embodiments, the filter assembly 14 mayinclude pivot 202, as exemplified in FIGS. 72-100. The pivot 202 may bebiased to the closed position of the portion of the filter assembly 14that contains the recess 198, such that during use, when the filtercartridge 194 is inserted into the filter assembly 14, the pivot 202allows the filter assembly 14 to more easily accept the cartridge 194,while also ensuring that the cartridge 194 is secured in place once ithas been fully inserted.

It will be appreciated that the filter assembly 14 may be formed of aflexible material that inherently provides a bias to close the filterassembly 14 once the filter cartridge 194 has been inserted, while alsoallowing for the cartridge 194 to be easily removed. Alternately, or inaddition, the filter assembly 14 may include a biasing member (e.g., aspring) to bias the filter assembly 14 in the closed position.Accordingly, pivot 202 may move to the closed position due to theresilience of the material it is made of and/or due to a biasing member.In other words, the pivot 202 may allow the filter assembly 14 to bemoved between an open, or removable, position in which the filtercartridge 194 may be removed from the cavity 158 and a closed positionin which the filter cartridge 194 may be secured in the cavity 158.

In some embodiments, the filter cartridge 194 may include a handle 204to assist with the removal of the cartridge 194 from the filter assembly14. For example, as exemplified in FIG. 78, the handle 204 may be usedto pull the cartridge 194 from the filter assembly 14. Alternately, orin addition, the filter cartridge 194 may include a grip 205 forassisting with the removal and/or replacement of the filter cartridge194. For example, as exemplified in FIG. 78, the filter cartridge 194has a grip 205 on either side. The grip 205 may assist a user byproviding a graspable surface to more easily remove the filter cartridge194. As exemplified in FIGS. 77 and 78, the grips 205 are formed of aportion of the two opposed sides of the filter cartridge 194 and arevisible to the user when the cartridge 194 is positioned within thefilter assembly 14 due to recesses provided in the sidewalls of thefilter assembly 14.

It will be appreciated that, in some embodiments, one or more filters inthe filter cartridge 194 may be independently, concurrently, and/orsubsequently removable from the filter assembly 14. For example, in someembodiments, the foam filter 118 may be removable from the filtercartridge 194 while the biological filter 116 remains in place, asexemplified in FIG. 81. Once the foam filter 118 has been removed, thebiological filter 116 may subsequently be removed. In some embodiments,both the foam filter 118 and the biological filter 116 may beconcurrently removable.

In some embodiments, the filter assembly 14 may include a filter seal206, as exemplified in FIGS. 72-100. The filter seal 206 may bepositioned between the filter assembly 14 and the filter cartridge 194,thereby reducing the likelihood of airflow leakage through the filterassembly 14.

In some embodiments, the side panels 192 of the filter cartridge 194 maybe shaped to improve the connection between to the filter cartridge 194and the filter seal 206. As exemplified in FIG. 83, the side panels 192each have a pointed, or V-shaped, top portion 195. The pointed topportions 195 improve the connection between the filter cartridge 194 andthe filter seal 206 by applying a pressure to the filter seal 206 suchthat a portion of the filter seal 206 is slightly displaced by the topportions 195. It will be appreciated that the top portions 195 may beany shape that improves the seal of the filter cartridge 194 in thefilter assembly 14. Such a seal may also be used, e.g., in theembodiment of FIG. 49 between lid 154 and filter housing 54.

In some embodiments, as exemplified in FIGS. 72-120, the filter assemblyor an outer surface of the filter assembly (e.g., a front cover 232) maybe formed of a single piece. Forming the filter assembly of a singlepiece may reduce the likelihood of airflow leakage in the filterassembly 14 and may generally improve the cleanliness of the filter mask10. For example, forming the filter assembly of a single piece allowsfor the reduction of the number of seams in the filter assembly 14.Reducing the number of seams may make the filter assembly 14 easier toclean and may reduce the accumulation of dirt on the filter mask 10. Areduction in the number of seams may also reduce the likelihood of rainor other liquids entering the filter mask 10. In some embodiments, thefilter assembly 14 may be formed of a smooth material. Reducing theroughness of the materials used in the filter assembly 14 may reduce thelikelihood of contaminates attaching to the filter assembly 14.Additionally, the use of smooth materials may make the filter mask 10easier to clean and/or disinfect.

In some embodiments, the filter assembly and/or the filter housingand/or the filter cartridge 194 may be formed of a translucent ortransparent material such that the filter assembly and/or the filterhousing and/or the filter cartridge 194 is at least partiallysee-through. Having the filter assembly and/or the filter housing and/orthe filter cartridge 194 at least partially see-through may allow a userto check the status of the filters, without requiring the user to removethe filter(s). Additionally, a transparent filter cartridge 194 allows auser to check that the filters have been sealed properly before theyfirst don the filter mask 10, such as if the biological filter 116 issupported by a holder as discussed with respect to FIGS. 42-45.

In some embodiments, as exemplified in FIGS. 72-100, the filter assembly14 may include a filter cover 230. The filter cover 230 may protect thefilter assembly 14 from dust and liquid, thereby reducing the likelihoodof damage to the filter mask 10. It will be appreciated that the filtercover 230 may be any shape and/or size that protects the filter assembly14. In some embodiments, as exemplified in FIGS. 72-100, the filtercover 230 has a front cover 232 and a rear cover 234. In someembodiments, as exemplified in FIGS. 72-100, the rear cover 234 may beformed of a first rear cover portion 234 a and a second rear coverportion 234 b. To form the assembled filter cover 230, the first rearcover portion 234 a is coupled to the second rear cover portion 234 band to the front cover 232. By separating the rear cover 234 into twopieces, the comfort of the filter mask 10 may be improved since theshape of the rear cover 234 may slightly change depending on the sizeand shape of a user's face. Additionally, forming the rear cover 234with two pieces may allow for easier assembly and disassembly of thefilter mask 10.

In some embodiments, the front cover 232 is formed of a single piece,reducing the number of seams as described above. It will be appreciatedthat the filter cover 230 may also be formed of a translucent ortransparent material to allow a user to check the status of the filter

FIG. 12 exemplifies an alternate method to secure a filter material,such as biological filter material 116, to filter housing 54. Asexemplified in FIG. 12, filter housing 54 comprises an outer filter bodyhousing 122 and an inner filter body housing 124. The biological filtermedia 116 may be positioned at a location at which the outer and innerfilter body housings 122, 124 abut and may be sandwiched therebetween.Accordingly, the biological filter media 116 may be secured to an innerface 126 of outer filter body housing 122 and/or the inner face 128 ofinner filter body housing 124 (e.g., by an adhesive such as silicon).Inner and outer filter body housings 122, 124 may be secured orremovably secured to each other by any means.

It will be appreciated that when filter assembly 14 is removed from maskbody 12 that the more porous filter media may be removed from each ofthe outer and inner filter body housings 122, 124 or an upper or lowerside of filter housing 54 that is exemplified in FIGS. 42-52.

Filter Assembly with Ionization

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, an ionizer may be providedto provide negative ions to the incoming air. One advantage of thisdesign is that, by charging the incoming air, particulate matter may becharged. This may cause the particulate matter to aggregate forminglarger particles that are more easily trapped by the filter media (e.g.,the more porous washable filter material such as a foam or felt filter).In addition, if an electrostatic precipitator is used, the particles aremore likely to be retained by the electrostatic precipitator.

A further advantage is that, by providing negative ions in the air beinginhaled, a person may produce increased levels of serotonin, which mayrelax a patient (increased levels of negative ions are theorized toincrease serotonin production in humans).

As exemplified in FIGS. 3 and 4, the air treatment member 46 maycomprise or consist of an electrostatic precipitator 50. Anyelectrostatic precipitator known in the air treatment arts may be used.The electrostatic precipitator 50 may have a tortuous path 52 defined bya plurality of passageways 74. Each passageway may be defined by opposed(e.g., upper and lower) walls 80. Each passageway 74 may have an upperside 76 and a lower side 78. As exemplified in FIG. 3, each of the upperand lower walls 80 defining a passageway 74 comprises or consists of anelectrostatic plate. Therefore, as air passes through the tortuous path52, the electrostatic plates may attract contaminants thereto.

As exemplified in FIGS. 3, 4, and 84, one or more ionizing sources 82,e.g., a corona discharge element, may be provided to generate negativeions to thereby ionize contaminants in the air flow passing through thefilter housing 54. These may be provided internal to and/or external ofthe electrostatic precipitator 50, or even if an electrostaticprecipitator 50 is not provided. For example, a corona discharge elementmay be provided in the upper air flow passage 62 and/or in one or moreof the passageways 74 of the tortuous path 52. The ionizing source maybe powered by 1-10 KV, 2-6 KV or 3-5 KV. Accordingly, the filter mask 10may be provided by an on board power source, which as one or morebatteries or capacitors.

Alternately, as exemplified in FIG. 4, the electrostatic precipitator 50may have a tortuous path 52 defined by solid non-conductive wall 80wherein a conductive member, e.g., an electrostatic mesh plate 84 isprovided on the upper and or lower surfaces of non-conductive walls 80so as to define the upper and lower sides 76, 78 of the passageways 74.

The electrostatic plates of FIG. 3 and the electrostatic mesh plates ofFIG. 4 may be made from, e.g., aluminum, nickel, stainless steel,copper, copper plated stainless steel, coper plated nickel, copperplated aluminum, brass plated aluminum, brass plated nickel or brassplated stainless steel. The electrostatic mesh plates of FIG. 4 may bewoven or non-woven mesh plates.

Different filters operate at different efficiencies for differentlysized particles. The removal efficiency of a particular filter, with aparticular pore size, may be improved by electrostatically enhancing thefilter material. In some embodiments, one or more ionizing sources 82may be used to enhance the removal efficiency of the filter assembly.For example, one or more filters may be exposed to positive or negativeions, electrostatically charging the filter media. Electrostaticallycharging the filter media, such as by one or more ionizing sources 82,may result in attractive forces or enhanced attractive forces betweenthe filter and airborne particles, thereby improving the removalefficiency of the filters. In other words, the filters may beelectrostatically enhanced to improve the removal of airborne particlesthat may otherwise have passed through the filters due to the pore sizeof the filter material.

In some embodiments, electrostatic enhancement of the filter materialmay be optimized for certain particle sizes, such as biologicalcontaminants. For example, HEPA material used in filters hasapproximately a 99.9% removal efficiency of particles sized at 0.3microns. However, HEPA filters have approximately a 99% removalefficiency of particles sized at 0.1 microns. Electrostaticallyenhancing the HEPA filter material may improve the removal efficiency of0.1 micron particles from 99% to approximately 99.97%.

It will be appreciated that, in some embodiments, a single filter may beelectrostatically enhanced to improve its removal efficiency, whileleaving one or more remaining filters uncharged. By selectively chargingfilters in the filter mask 10, the lifetime of one or more filters maybe increased at the expense of the other filters. For example, the foamfilter 118 may be electrostatically charged to improve the lifetime ofthe biological filter 116, or vice versa. An advantage of selectivelycharging filters in the filter mask 10 is that the lifetime of filtermaterial that is in short supply in times of crises may be prolonged.

Assisted Breathing

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, one or more fans may beprovided to assist in drawing air into or out of the filter mask 10. Thefan may have a motor and a propeller to generate air flow through themask 10. The fan may be provided downstream of the cavity 158 in adirection of flow of air, relative to inhalation by a user. For example,a fan may be provided to assist a person during inhalation. Alternately,or in addition, a fan may be provided to assist a person wearing themask during exhalation.

Accordingly, in some embodiments, one or more fans 130 may be providedfor assistance during inhalation and a different fan or fans 130 may beprovided to assist during exhalation. In such cases, separate inhalationand exhalation passages may be provided in the filter assembly 14. Thefan may be actuated by a sensor (e.g., a pressure sensor or a flowsensor) provided in the air flow passage having the fan.

For example, as exemplified in FIGS. 98-100, the filter mask 10 has twofans 130. The first fan 130 a may assist with inhalation of the user andthe second fan 130 b may assist with exhalation of the user. Asexemplified, the first fan 130 a operates to blow air into the filtermask 10, thereby assisting with inhalation, while the second fan 130 boperates to blow air out of the filter mask 10, thereby assisting withexhalation. As described previously, as exemplified, each of theinhalation side 146 and the exhalation side 148 may have a foam filter118 and/or a biological filter 116.

Fan 130 may produce an air flow of 3-18 liters/minute, optionally 6-18liters/minute or 12-18 liters/minute or optionally about 6liters/minute.

In other embodiments, a single fan may be used. The fan may bepositioned in a common passage used for inhalation and exhalation andthe direction of rotation of the fan may be altered based on whether theperson wearing the mask is inhaling or exhaling. The direction ofrotation of the fan may be adjusted by a sensor (e.g., a pressure sensoror a flow sensor) provided in the air flow passage. Accordingly, in someembodiments, air may travel past the fan 130 during both inhalation andexhalation.

If a fan is used only for inhalation, then the fan may be positioned ina common passage used for inhalation and exhalation or, alternately asexemplified in FIGS. 19 and 101-120, the fan 130 may be provided in apassage for inhalation 132 and a separate passage may be used forexhalation (the exhalation passage 134). It will be appreciated that anenergy storage member 136, such as a battery or capacitor, may beprovided at any location on the filter mask 10 and may be provided inthe filter assembly 14. Accordingly, if the filter assembly 14 isremovable, the energy storage member 136 may be recharged or replacedwhen the filter assembly is removed for, e.g., cleaning.

In some embodiments, a top portion of the filter cartridge 194 mayinclude a fan port 155 for facilitating airflow through the fan 130. Asexemplified in FIGS. 84 and 85, the lid 154 has a fan port 155 and thefan 130 is located downstream (relative to an inhalation) of the fanport 155. The fan port 155 may be used to supply air flow to the fan 130from the common passage for inhalation and exhalation. For example, as auser inhales, the air passes through the bottom of the filter assembly14, through the filter media 116 and 118. The air then passes throughthe fan port 155 and through the fan 130 to the user. When the userexhales, the air passes through the fan 130, through the fan port 155,and out of the filter assembly 14 after passing the filter media 116 and118. As exemplified in FIGS. 84 and 85, the fan port 155 is the onlyopening in the lid 154 with the rest of the lid 154 being air pervious,thereby facilitating the use of a common airflow passage. In someembodiments, the fan port 155 may occupy less than 50% of the lid 154.If a single fan port is provided, then fan 130 optionally uses apropeller instead of an impeller.

In some embodiments, the size of the fans 130 may vary depending on thedesired use of the filter mask 10. For example, a larger mask 10 mayrequire larger fans 130 to assist with the increased volume of air. Itwill be appreciated that the projected area of the fan(s) 130 onto thefilter 116 may be the same as the projected area of the filter 116. Inother words, the surface area of the air transfer region from the filter116 to the fan 130 may be the same as the surface area of the receivedair transfer region in the fan 130. Equalizing, or approximatelyequalizing, the projected areas of the filter 116 and the fan 130 mayreduce backpressure within the filter mask 10, thereby improving thefunction and/or comfort of the user. It will be appreciated that, insome embodiments, the projected areas of the filter 116 and the fan 130may be differently sized.

In some embodiments, the top portion of the filter cartridge 194 mayhave a plurality of fan ports 155. For example, as exemplified in FIGS.98-100, the lid 154 includes a first fan port 155 a and a second fanport 155 b. The first fan port 155 a is located on the inhalation side146 in the inhalation passage 132. The second fan port 155 b is locatedon the exhalation side 148 in the exhalation passage 134. As exemplifiedin FIGS. 98-100, the first fan 130 a is located downstream (relative toan inhalation) of the first fan port 155 a and the second fan 130 b islocated upstream (relative to an exhalation) of the second fan port 155b. When a user inhales, air enters the filter cartridge 194 and passesthrough the filter media 116, 118, through the first fan port 155 a, andthrough the fan 130 a to the user. When the user exhales, air flowsthrough the second fan 130 b, through the second fan port 155 b, throughthe filter media 116, 118, and out of the filter cartridge 194.

As exemplified, the flow passage between the filter assembly 14 and thevolume 28 in FIG. 19 is common to inhalation and exhalation (e.g., theremay be a common header). In such a case, a one-way valve may be providedto prevent or inhibit the flow of air through a passageway in adirection reverse to the direction of the flow of air induced by a fan130. For example, in the embodiment of FIG. 19, a one-way valve 138 isprovided upstream of fan 130. It will be appreciated that the valve 138may be provided downstream of fan 130. Any one-way valve may be used.The one-way valve may be actuated by flow therethrough or a sensor(e.g., a pressure sensor or a flow sensor).

In some embodiments, the fan 130 may have a relatively low head ofpressure due to the use of propeller instead of an impeller. Duringexhalation, the assistance of the fan 130 may be overcome due to the lowhead, thereby allowing a single fan to assist with inhalation whilemaintaining ease of exhalation. Such a fan may be used in an embodiment,such as is exemplified in FIGS. 82-85 wherein a common passage isprovided for inhalation and exhalation.

It will be appreciated that, as exemplified in FIG. 19, if a one-wayvalve is used and/or if a fan 130 is used, then more porous filter media118, 120 need not be provided downstream of the biological filtermaterial 116.

Charging

In accordance with this aspect, which may be used by itself or incombination with one or more aspects, if the mask includes anelectrically powered component, such as a fan 130 or a light source 250(such as an LED), then the mask may include one or more energy storagemembers, such as one or more batteries or capacitors, and the one ormore energy storage members may be removable for replacement and/orrecharging and/or recharging and the one or more energy storage membersmay be recharged while positioned in the mask.

In some embodiments, the energy storage member 136 may be rechargeablewithout removing the filter assembly 14. Accordingly, as exemplified inFIGS. 72-120, the filter mask 10 has a charging port 137, which may belocated on the filter assembly 14. The charging port 137 may allow auser to charge the energy storage member 136 by electrically connectingthe energy storage member 136 to an external power source (not shown) bya power cord that is insertable into the charging port 137. For example,the charging port 137 may be a USB port. In some embodiments, the energystorage member 136 may be charged while the mask is in use.

In some embodiments, a second energy storage member 136 may be connectedto the first energy storage member 136 through the charging port 137.The second energy storage member 136 may charge the first energy storagemember 136, thereby allowing the user to continue wearing the mask 10while the first energy storage member 136 charges.

In some embodiments, the energy storage member 136 may be chargedwirelessly. For example, the user may remove the mask 10 and place themask 10 on an induction charger. The induction charger may charge theenergy storage member 136 without the need of a wire to charge theenergy storage member 136. Induction charging may improve the seal ofthe mask 10, since the energy storage member 136 need not be removedfrom the mask 10 to charge.

In some embodiments, the energy storage member 136 may be removed fromthe mask 10. The energy storage member 136 may be replaced with a secondenergy storage member 136 that is fully charged, allowing the mask 10 tobe used while the first energy storage member 136 charges. For example,as exemplified in FIGS. 105-120, the energy storage member 136 may beremoved from the mask 10. As exemplified, the energy storage member 136is a battery. The user may remove the mask 10, providing an opening tovolume 28 where the user's face rests in the mask 10. The battery 136may be detached from the filter assembly 14 and removed through theopening in the mask 10. The battery 136 may then be replaced orrecharged before being returned to the mask 10. The use of a removableenergy storage member 136 may allow the seal on the mask 10 to beimproved, since the energy storage member 136 can only be removed by theuser removing the mask 10.

Alternately, as exemplified in FIG. 117, the energy storage member 136may be accessible when the mask is being worn and may be removed withoutremoving any component of the filter assembly 14.

Regenerative Charging

In accordance with this aspect, which may be used by itself or incombination with one or more aspects, the fan 130 may be used forregenerative energy recovery. When a person breathes in and out, themotion of the breath provides fluidic energy. Positioning the fan 130 inthe exhaust flow of a user's breath may assist in recovering somefluidic power through use of the fan 130. An advantage of this aspect isthat air, which is exhaled past the fan, may cause the fan to rotate inan opposite direction compared to the direction used for blowing air.Rotating the fan in the opposite direction may allow the fan to be usedas a generator. The generator may be coupled to the rechargeable energystorage member 136, such as a battery.

Accordingly, a user's exhalation may be used to, e.g., increase and/ormaintain the charge of a battery within the mask, to allow the mask tooperate for longer periods of time without requiring external charging.The regeneration may use one or more fans 130. For example, in someembodiments, there may be a single passage for intake and exhaust with asingle fan 130. During inhalation, the fan 130 may assist by rotating apropeller in a first direction, powered by the energy storage member136, thereby actively blowing air into the mask 10 for the user tobreathe. During exhalation, the user's breath may overcome the fan 130,causing the fan 130 to rotate in a second direction. As the propeller ofthe fan 130 rotates in the second direction, the propeller may act as agenerator. The generator may be coupled to the energy storage member136, allowing the generator energy to recharge the energy storage member136.

In some embodiments, the filter assembly 14 may have a common airpassage for inhalation and exhalation. Accordingly, a fan inlet (i.e.for inhalation) of the fan may be located on a bottom side of the fan,while the outlet (i.e. for inhalation) may be located on the side of thefan. Positioning the inlet on the bottom and the outlet on the side mayhelp with overpowering the fan 130 on a user's exhale to generateenergy. Accordingly, during inhalation, the air flows through the bottomof the fan 130 and out the side of the fan 130. During exhalation, theuser overpowers the fan 130 to allow air to move through a top of thefan 130, causing the fan 130 to rotate in the second direction. Theexhaled air may pass through the top of the fan 130 and out the bottom(the inlet) of the fan 130, thereby allowing the fan 130 to be used as aregenerator.

In some embodiments, the filter assembly 14 may have separate airpassages for inhalation and the exhalation. For example, as exemplifiedin FIGS. 98-100, the filter assembly 14 has an inhalation passage 132 onthe inhalation side 146 and an exhalation passage 134 on the exhalationside 148. Accordingly, to regenerate energy using the exhale of a user,a plurality of fans 130 may be used. For example, as exemplified inFIGS. 98-100, a first fan 130 a may be provided on the inlet side whilea second fan 130 b may be provided on the outlet side. As the userinhales, the first fan 130 a may assist with blowing air into the mask10. As the user exhales, the second fan 130 b may act as a generator asdescribed above, thereby recovering the fluidic energy caused by theuser's exhale. The recovered energy may be used to power and/or rechargeother components of the mask 10.

Light Source

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the mask 10 may include alight source 250. The light source 250 may be controlled by one or morebuttons on the mask 10, as will be described subsequently. An advantageof having a light source 250 on the mask 10 may be that a user does notneed to hold an additional light source in areas where airbornecontaminates or insufficient light prevent the user from being able tosee properly. Alternately, or in addition, the light source 250 may beused to indicate the status of electrical components in the mask 10. Astatus light source may, for example, allow a user to determine when themask needs to be charged or if a component has failed.

The light source 250 may be any light source used in the mask arts andmay be a light emitting diode (LED). The LED 250 may indicate that theenergy storage member 136 needs to be charged.

In some embodiments, the light source 250 may include one or more lightpipes 252, as exemplified in FIGS. 116-120. The light pipe 252 mayincrease the dispersion of the light source 250 and/or may allow lightto be emitted from a location distal to the light source 250 itself.Accordingly, the light source 250 may be used as a flashlight. Forexample, as exemplified in FIGS. 116-120, the light pipes 252 extendfrom a rear side of the filter housing 54 to the front of the filterhousing 54. As exemplified, the light sources 250 are positioned at therear side of the filter housing 54. Accordingly, the light pipes 252allow the light sources 250 to be positioned at the rear side of thefilter housing 54, such as on a printed circuit board, while stillemitting light from the front of the mask 10, improving the usability ofthe flashlight for the user.

In some embodiments, the light pipe 252 may be triangularly shaped, asexemplified in FIGS. 133 and 134. The triangularly shaped light pipe 252may include a reflector on the top surface of the light pipe 252. Thelight pipe and/or reflector may be used to emit light in a particulardirection, e.g., forwardly. As exemplified, the triangularly shapedlight pipes 252 are used to emit light in a forward direction, whileallowing the light source 250 to remain within the filter assembly 14.During use, the light source 250 may emit light upwardly through thelight pipe 252. Once the light emitted from the light source 250reaches, e.g., the reflector of the light pipe 252, the reflectorreflects the emitted light in a forward direction. It will beappreciated that the angle of reflection may vary depending on thedesired use of the filter mask 10. For example, in some embodiments, theangle of reflection may be in the range of 30-150°, optionally 45-135°,optionally 60-120°, or optionally 80-100°. It will be appreciated thatthe angle of reflection may be any angle.

In some embodiments, the direction of the emitted light may becontrolled by the shape of the filter housing 54. As exemplified inFIGS. 135 and 136, the filter housing 54 is contoured to form a U-shape55. The light sources 250 are located on either side of the U-shape 55,allowing the light sources 250 to be located above the rest of thefilter assembly 14. Raising the light sources 250 above the plane of thefilter assembly 14 may allow light to more easily be emitted outwardlyfrom the filter mask 10 without a light pipe.

Electronics Unit

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the mask 10 may include anelectronics unit 260. It will be appreciated that the electronics unit260 may be used to control any one or more of the electronic componentsof the mask 10. For example, the electronics unit 260 may be used forcontrolling, including, but not limited to, the speaker 32, themicrophone 33, the electrostatic precipitator 50, one or more fans 130,the energy storage member 136, the regenerator, the ionizing sources 82,charging the energy storage member 136, the light source 250, or anycombination thereof.

In some embodiments, the electronics unit 260 may include one or morebuttons for controlling one or more electronic components of the mask10. The buttons may be located on the electronics unit 260 and/or on themask body 12. For example, as exemplified in FIGS. 100 to 115, the mask10, e.g., the filter assembly includes a plurality of buttons 262. Thebuttons 262 may be used to control any of the electrical components ofthe mask 10. For example, a first and a second button 262 may controlthe volume of the speaker 32 and/or the volume of the microphone 33.Another button 262 may turn the light source 250 on and off. Anotherbutton 262 may turn the fan 130 on and off. Another button 262 maycontrol the Bluetooth receiver for connecting the speaker 32 and/ormicrophone 33 to an external device, such as a computer and/or mobiledevice. As exemplified in FIGS. 116-120, the button 262 may be used toturn on and off the fan 130 and/or the light source 250.

The electronics unit 260 may be powered by one or more energy storagemembers 136. For example, in some embodiments, the electronics unit 260may include an energy storage member holder 264, as exemplified in FIGS.116-120. The energy storage member holder 264 may be used to hold theenergy storage member 136 in electrical contact with the electronicsunit 260.

In some embodiments, the electronics unit 260 may include a foam 261, asexemplified in FIG. 134. It will be appreciated that the foam 261 may bean open cell foam and/or a closed cell foam. The foam 261 may be used toprovide support for the energy storage member 136 and/or the electronicsunit 260. For example, the foam 261 may secure the energy storage member136 and/or the electronics unit 260 in place within the filter assembly14. The foam 261 may also act as a shock absorber for the energy storagemember 136 and/or electronics unit 260 in the event that the mask 10 isdropped. The foam 261 may also be used to provide a seal against dustand/or liquids to provide additional protection to the electronics unit260.

In some embodiments, the button 262 may be used to turn on and off theenergy storage member 136. Once the energy storage member 136 isactivated, additional buttons 262 may control the individual componentsof the electronics unit 260.

In some embodiments, the buttons 262 may be located on the mask 10separate from the electronics unit 260. For example, the buttons 262 maybe located on one or more of the mask body 12, the filter assembly 14,or the filter cartridge 194, optionally on an outer surface thereof suchthat the buttons may be actuated while the mask is being worn.

In some embodiments, the light source 250 may be positioned on theelectronics unit 260. The light pipes 252 may allow the electroniccomponents of the light source 250 to be positioned with the rest of theelectronics unit 260, while still emitting light from the front of themask 10. Grouping the electronics into a single location may reducemanufacturing costs and may improve the ease of repairing and/orreplacing parts.

In some embodiments, the electronics unit 260 may be removable from themask 10. For example, in some embodiments, the electronics unit 260 maybe a part of the filter cartridge 194. Accordingly, a user may removethe filter cartridge 194 with the electronics unit 260 and subsequentlythe user may remove the electronics unit 260, such as if the electronicsunit 260 needs to be replaced. For example, as exemplified in FIGS.101-115, the electronics unit 260 is removable with the filter cartridge194 and is subsequently removable from the filter cartridge 194

In some embodiments, the electronics unit 260 may be separatelyremovable from the mask 10. Accordingly, the electronics unit 260 may bepositioned such that the electronics unit 260 may be removed without theuser removing the mask 10. As exemplified in FIGS. 116-120, theelectronics unit 260 is removable from the filter housing 54.

It will be appreciated that the electronics unit 260 may be mounted tothe mask 10 by any means. For example, the electronics unit 260 may bemounted to the mask 10 by, including, but not limited to, magnets,mechanical fasteners, clips, friction fit, rib and grooves, or anycombination thereof. For example, as exemplified in FIGS. 116-120, theelectronics unit 260 includes two clips 266. The clips 266 may be usedto mount the electronics unit 260 to a mounting member on the filterhousing 54 (not shown).

Sanitization

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the mask 10 may be sanitizedby, e.g., steam cleaning and/or ozonation and/or UV light. An advantageof using steam cleaning, ozonation and UV light to sterilize the mask 10is that the mask may be cleaned without extreme heat or high levels ofUV radiation.

In accordance with this aspect, after use, the mask 10 may be placed inthe cleaner 300, which may use any sterilization method and hereinafterreferred to as a steam cleaner 300 for convenience, as exemplified inFIGS. 121-122. The steam cleaner 300 may include a container 302, awater supply 304, and a steamer 306 (or other sterilization source). Thecontainer 302 may receive the mask 10 for cleaning the mask. The steamer306 may use the water supply 304 to generate steam 308. For example, thesteamer 306 may include a heater, a pump, and a nozzle for generatingand dispensing steam. The steam 208 may then be dispersed or otherwiseinserted into the container 302.

It will be appreciated that the operating temperature of the steamcleaner 300 may have a wide range. The temperature of the steam 208 mayvary depending on the type of contaminate that the mask 10 has beenexposed to and the length of time that the steam is applied. Forexample, in some cases, a temperature of 60° C.-80° C. may be sufficientto degrade a viral contaminate. Accordingly, the steam 308 may be heatedto a sufficient temperature to disinfect the mask 10, without causingsignificant damage to the mask 10.

In some embodiments, the mask 10 may be steam cleaned with theelectronics unit 260 in the mask 10. As exemplified in FIG. 121, themask 10 is positioned within the container 302 with the electronics unit260 still in place. In some embodiments, the steam cleaner 300 mayinclude a cooling system 310 for cooling the electronics unit 260 and/orthe energy supply member 136 as the mask 10 is being cleaned. Thecooling system 310 may be used to selectively cool a portion of the mask10 that may be damaged by higher heat. In some embodiments, one or morefans 130 within the mask 10 may be turned on while the mask 10 is beingcleaned, thereby lowering the internal temperature of the mask 10.

In some embodiments, components of the mask 10 that may be damaged bysteam cleaning or moisture, if the electronics unit 260 and the energystorage member are not sealed, may be removed prior to cleaning, asexemplified in FIG. 122. For example, the electronics unit 260 and/orenergy storage member 136 may be removed prior to the mask 10 beingsteam cleaned. As described above, the electronics unit 260 may beremoved separately from the filter assembly 14 and/or the filtercartridge 194, or may be removed concurrently with the filter assembly14 and/or the filter cartridge 194. Removing the electronics unit 260prior to steam cleaning may allow the mask 10 to be subjected to highertemperatures to improve the sanitization of the mask 10.

In some embodiments, the mask 10 may be charged while being steamcleaned. For example, the mask 10 may be connected to an external powersupply 312 by port 137 to charge the energy supply member 136, withinthe container 302. In some embodiments, the external power supply 312may use wireless charging, such as induction charging, to charge themask 10 while the mask 10 is being cleaned.

In some embodiments, the external power supply 312 may be locatedoutside of the container 302, as exemplified in FIG. 122. In suchembodiments, the electronics unit 260 may be removed from the mask 10and plugged in and/or wireless charged by the external power supply 312.

Circulation Pattern

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the inlet and outlet airflow passage may be configured to produce circulation of air withinvolume 28 between a mask and the face of a user. An advantage of thisaspect is that air, which is exhaled into the volume, may be morecompletely removed from the volume, which may result in a reduction ofcarbon dioxide in the volume. A further advantage is that fogging on theinner surface of the face plate may be reduced or essentiallyeliminated.

In accordance with this aspect, separate inlet and outlet posts mayoptionally be provided. For example, an inlet port may be provided thatis optionally closed by a valve (e.g., a flexible diaphragm) and whichopens when a person inhales and an outlet port may be provided that isoptionally closed by a valve (e.g., a flexible diaphragm) and whichopens when a person exhales.

As exemplified in FIGS. 30 and 30-41, filter mask 10 may have one ormore passages, which are provided on one lateral side of filter mask 10,for air traveling into volume 28 during inhalation on one lateral sideof filter mask 10 and one or more passages, which are provided on theother lateral side of filter mask 10, for air traveling out of volume 28during exhalation. As exemplified in FIG. 30, filter mask 10 has twoinlet conduits 42 a, 42 b through which air travels during inhalation.These are provided on the right lateral side of filter mask 10, asviewed in FIG. 30. Filter mask 10 also has two outlet conduits 42 c, 42d through which air travels during exhalation. These are provided on theleft lateral side of filter mask 10, as viewed in FIG. 30. As a result,a circulation pattern is developed inside volume 28. As exemplified,incoming air introduced into volume 28 may tend to travel down the rightside of the face of a user (as exemplified by Arrow A) and outgoing airexhaled by a user into volume 28 may tend to travel up the left side ofthe face of a user (as exemplified by Arrow B). This circulation willtend to inhibit the buildup of carbon dioxide in volume 28 as air willtend to travel in a generally circular pattern inside volume 28 andessentially cause air, which is exhaled to exit volume 28.

The circulation pattern may be enhanced in one or more ways. Forexample, the use of a fan 130 inhalation side 146 will tend to cause airto enter and travel down the right side of volume 28. If fan 130operates at all times to draw air into volume 28, then exhaled air willtend to travel upwardly on the left side of volume 28.

Alternately or in addition, an eye shield 168, as discussedsubsequently, may be provided. If eye shield 168 is provided, then eyeshield 168 may have an upper surface that is configured to direct air toone side of volume 28 (e.g., eye shield 168 below inlet conduits 42 a,42 b may direct air to the right side of volume 28 as exemplified inFIG. 30). Alternately, or in addition, an eye shield 168 may be providedbelow outlet conduits 42 c, 42 d to assist in directing air into outletconduits 42 c, 42 d. Accordingly, for example, the upper surface of eyeshield 168 may extend from the inner side thereof sidewardly anddownwardly, e.g., it may have a linear upper surface that extends at aconstant angle downwardly or the upper surface may be curved downwardlyfrom the inner side of eye shield 168.

During deep inhalation, it is possible that air may also be drawn intovolume 28 via outlet conduits 42 c, 42 d, see for example FIG. 31. Inorder to prevent such a flow pattern, as exemplified in FIGS. 38-41, theinlet passage and/or the outlet passage may be provided with a valve170, 172 to close the passage. Inlet closure valve 170 may be configuredto close automatically during exhalation and/or to automatically openupon inhalation. Accordingly, as exemplified in FIGS. 38-41, inletclosure valve 170 may be placed on the downstream side of inlet conduit42 a. Inlet closure valve may be pivotally mounted and may be optionallyspring biased to a closed position. Accordingly, when a user inhales,inlet closure valve 170 may be pivoted to the open position shown inFIG. 38 by the incoming air. When a user finishes inhaling, inletclosure valve 170 may then return to the closed position due to thebiasing member. Alternately or in addition, air traveling upwardlytowards inlet conduit 42 a may drive or assist in driving inlet closurevalve 170 to the closed position. When in the closed position, inletclosure valve 170 will cause air to exit via outlet conduit 42 c.

Alternately, or in addition, as exemplified in FIGS. 38-41, the outletpassage may be provided with outlet closure valve 172 to close thepassage. Outlet closure valve 172 may be configured to closeautomatically during inhalation and/or to automatically open uponexhalation. Accordingly, as exemplified in FIGS. 38-41, outlet closurevalve 172 may be placed on the downstream side of outlet conduit 42 c.Outlet closure valve 172 may be pivotally mounted and may be optionallyspring biased to a closed position. Accordingly, when a user exhales,outlet closure valve 172 may be pivoted to the open position shown inFIG. 38 by the outgoing air. When a user finishes exhaling, outletclosure valve 172 may then return to the closed position due to thebiasing member. Alternately or in addition, air traveling downwardlytowards through the filter media 46 may drive or assist in drivingoutlet closure valve 172 to the closed position. When in the closedposition, outlet closure valve 172 will cause air to travel throughinlet conduit 42 a.

Offset Face Plate

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the inlet and outlet airflow passage may be configured to reduce or eliminate air flow in and/orover the volume 28 between a mask and the face of a user. This may beachieved by positioning the inlet and outlet away from a face plate orby configuring the outlet to direct air away from the face plate. Anadvantage of this aspect is that air is not exhaled into the volume orover the interior of the face plate, which may result in a reduction orelimination of carbon dioxide and/or condensation in the volume 28. Afurther advantage is that fogging on the inner surface of the face platemay be reduced or essentially eliminated. Accordingly, a face plate maybe provided (offset from but closely positioned to a person's face) toprotect the user from droplets exhaled by a person which may have abiological contaminant.

In accordance with this aspect, the air inlet and air outlet of thefilter mask may be positioned such that inhaled and exhaled air does notpass through or near the volume between the face plate and the user'sface.

As exemplified in FIGS. 86-97 and 113-115, the face plate 20 of thefilter mask 10 is spaced apart from, and does not contact, the user'sface. It will be appreciated that at least some of the face plate 20 maycontact the user's face depending on the desired use of the filter mask10. As exemplified, the face plate 20 is positioned between thesubstrate 174 and the filter assembly 14. As described previously, theinlet and/or outlet may be positioned on the lower side of the filterassembly 14 (as exemplified in FIG. 89 a common inlet and outlet mayface downwardly). Accordingly, the airflow into and out of the filtermask 10 does not pass through or near the volume 28 between the faceplate 20 and the user's face. By positioning the inlet and/or outletpassages 42 to reduce or remove airflow in front of user's face, theuser's face may be protected by the face plate 20 without the need forsealing the face plate 20 against the user's face. Accordingly, the faceplate 20 may be used to protect a user's eyes against projectilecontaminates, such as from a coughing person, while still allowing forair flow in front of the user's face to improve the comfort of the user.

Another possible advantage is that the offset face plate may improve theadaptability of the filter mask to be used for a variety of head shapesand sizes. By offsetting the face plate and changing the position of theairflow conduits 42, the substrate 174 and/or sealing member 26 may beused to create the seal against the user's face, while not requiring theface plate 20 to be fitted to a user, thereby allowing the face plate 20to be used for more face shapes and sizes.

In some embodiments, the face plate 20 may be permanently attached tothe filter mask 10, as exemplified in FIGS. 1 and 127-132 For example,the face plate 20 may form an integral part of the mask body 12. Forexample, the face plate 20 may be integrally molded with a portion ofthe mask body 12. In some embodiments, both the portion of the mask body12 and the face plate 20 may be transparent. In other words, the portionof the mask body 12 that includes the integrally molded face plate 20may be the transparent portion 13 of the mask body 12. As exemplified inFIGS. 127-132, the face plate 20 extends outwardly from the transparentportion 13 of the mask body 12.

Mounting the Face Plate

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, a supplemental face plate tooverlie the eyes of a user may be removably mounted to the mask. Anadvantage of this aspect is that a user may remove the supplemental faceplate from the mask in situations where a supplemental face plate is notneeded. Alternately, or in addition, the supplemental face plate may beremoved from the mask to facilitate cleaning and/or disinfecting of theface plate and/or mask.

In accordance with this aspect, the supplemental face plate 20 may bepositioned, once mounted to the mask, such that the supplemental faceplate is spaced in front of the eyes of the user and spaced therefrom(see for example FIGS. 89 and 115). The supplemental face plate may beshaped and sized to overlie the front of the face of a user asexemplified in FIG. 89 or the supplemental face plate 20 may be shapedand sized to extend around the side of the head of the user asexemplified in FIG. 115.

The supplemental face plate may be secured in any manner. For example,the supplemental face plate 20 may be removably mounted between thefilter assembly 14 and the mask body 12, as exemplified in FIGS. 86-97.Alternately, as exemplified in FIGS. 113-115, the supplemental faceplate 20 may be mounted to the mask body 12. The face plate 20 may bemounted to the mask 10 by, including, but not limited to, magnets,mechanical fasteners, clips, hook and loop fasteners, groove and rib,standoffs, a friction fit or any combination thereof.

In some embodiments, the face plate 20 may be mounted to the mask body12 by one or more removable fasteners 270. For example, as exemplifiedin FIGS. 123-126, the face plate 20 is removably mounted to the maskbody 12 by screws 270. As exemplified, the two screws 270 secure eachside of the face plate 20 to the mask body 12. As shown, the face plate20 has first fastener holes 272 and the mask body 12 has second fastenerholes 274. As exemplified, the first fastener holes 272 are located on amask body abutment surface 276, while the second fastener holes 274 arelocated on a face plate seat 278. During use, the mask body abutmentsurfaces 276 on the face plate 20 are positioned to abut and rest intheir respective face plate seats 278 on the mask body 12. The screws270 are then threaded through the first fastener holes 272 into thesecond fastener holes 274, thereby securing the face plate 20 to themask body 12. It will be appreciated that there may be any number offasteners used to secure the face plate 20 to the mask body 12.

If the supplemental face plate 20 is removably mounted between thefilter assembly 14 and the mask body 12, then the mounting assembly 210may extend through an opening in the supplemental face plate 20. Forexample, as exemplified in FIGS. 86-97, the supplemental face plate 20includes an opening 21, a male face plate portion 213, and a female faceplate portion 221.

During use, the male portion 212 of the filter assembly 14 is insertedinto the female face plate portion 221 and secured as describedpreviously. The male face plate portion 213 may be inserted into thefemale portion 220 on the substrate 174 and secured as describedpreviously. The opening 21 allows for airflow between the filterassembly 14 and the mouth of the user. Alternately, the male portion 212of the filter assembly 14 may be inserted through an opening in thesupplemental face plate and then into the female portion 220 on thesubstrate 174 and the supplemental face plate 20 may be sandwichedtherebetween.

It will be appreciated that one or more seals 216 may be positionedbetween each of the filter assembly 14 and the face plate 20, and thesubstrate 174 and the face plate 20. In the embodiment of FIGS. 113-115,the supplemental face plate 20 is mounted to the upper portion of themask body and, optionally, is removably mounted thereto.

In some embodiments, when the face plate 20 is mounted to the mask 10,the supplemental face plate 20 may be locked in position. Locking thesupplemental face plate 20 to the mask 10 may improve the stability ofthe supplemental face plate 20 as a user moves their head. Thesupplemental face plate 20 may be unlocked to remove the supplementalface plate 20 from the mask 10.

Securing Mechanism

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the securing mechanism usedto secure the filter mask to the face of a user may be positioned toallow a user to wear additional headgear. An advantage of this aspect isthat a user may wear additional protection, such as a hat, hard hat,sweat band, goggles, etc. without affecting the comfort of the filtermask.

In accordance with this aspect, in some embodiments as exemplified inFIGS. 96 and 141-147, a securing mechanism 320 may pass along thelateral sides of the head of a user, rather than across the forehead. Insome embodiments, a portion of the securing mechanism 320 may pass overthe top of a user's head, without interfering with a user's forehead orface.

As exemplified in FIGS. 95 and 96, the securing mechanism 320 includesthree straps 30. Two of the straps 30 pass along the sides of the headof a user and one of the straps 30 passes over the rear top portion ofthe user's head. Additionally, the supplemental face plate 20 is offsetfrom the face of the user, as described above. The position of thesecuring mechanism 320 and the supplemental face plate 20 may allow auser to wear a hardhat 240, as exemplified in FIGS. 92-97, withoutcausing discomfort to the user. Accordingly, a user may improve theircomfort and protection levels without sacrificing comfort and safety. Itwill be appreciated that, in some embodiments, only one strap 30 maypass behind a person's head and only one strap may pass over the top ofa person's head. Accordingly, for example, lower strap 30 in FIG. 96 mayoptionally not be provided.

In some embodiments, the position of the securing mechanism 320 mayallow for a user to wear other forms of protection, such as glasses orgoggles, without affecting the protection and/or comfort of the user.The glasses may be positioned on the inner side of the supplemental faceplate 20 that faces the user. For example, when the securing mechanism320 passes along the sides of the head of a user, a user may still beable to wear goggles to protect their eyes. In some embodiments, asdescribed above, a portion of the securing mechanism 320 may pass overthe top of the user's head, without interfering with their forehead orface. This positioning allows for a user to wear goggles withoutaffecting the seal of the goggles on the user's face, thereby improvingthe safety of the user.

Securing Mechanism with Rigid Portions

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the securing mechanism usedto secure the filter mask to the face of a user may include first andsecond rigid portions. An advantage of this design is that the first andsecond rigid portions may be shaped and/or positioned to improve thecomfort of the user when wearing the filter mask. Another advantage ofthis aspect is that the first and second rigid portions may allow a userto wear additional protection, such as a hat, hard hat, sweat band,goggles, glasses, etc. without affecting the comfort of the filter mask.

For example, as exemplified in FIGS. 141-147, the securing mechanism 320includes a first strap 30 a having a first side portion 322 a and asecond side portion 322 b. As exemplified, the first side portion 322 aextends over a portion of a first lateral side 323 a of the head of theuser (the right side as exemplified in FIG. 145), while the second sideportion 322 b extends over a portion of a second lateral side 323 b ofthe head of the user (the left side as exemplified in FIG. 145). Asexemplified in FIGS. 142 and 143, the first side portion 322 a has amask body engagement end 324 a and a rearwardly disposed opposed end 326a, and the second side portion 322 b has a mask body engagement end 324b and a rearwardly disposed opposed end 326 b. The mask body engagementends 324 a, 324 b may be coupled to the mask body 12 at the strapattachments 90.

As exemplified in FIGS. 141-147, the side portions 322 a, 322 b arerigid. The term “rigid” with respect to the side portions 322 a, 322 bis defined as being sufficiently stiff so as not to collapse and putpressure on the left and right sides of the head of a user when the useris wearing the mask 10. Accordingly, the securing mechanism will notapply pressure, or a level of pressure, to the left and right sides ofthe head of a user that will cause discomfort or pain. The securingmechanism may be shaped so as to not directly (by the side portionitself contacting the side of a head of a user) or indirectly (by theside portion contacting the temples of glasses which are worn by a user)apply pressure to the sides of a hear of a user wearing the mask. Thisis particularly the case if the user is wearing glasses while wearingthe mask. Accordingly, the portion of the securing member that wouldoverlie the temples of glasses may be rigid and shaped so as to notpress inwardly on the temples of the glasses and is optionally spacedoutwardly from the temples of the glasses. Accordingly, the sideportions 322 a, 322 b may be made from a rigid plastic, which mayinclude, but is not limited to, ABS, HDPE, nylon, and/or polycarbonate.

It will be appreciated that a strap that includes a rigid portion mayhave an adjustable length. For example, a rear end of the rigid sideportions 322 a, 322 b may be connected by an adjustable band 340 and/orthe side portions may include a part that has an adjustable length.Adjustable band 340 may be any strap member that has a variable length,such as an elastomeric strap or a non-elastomeric strap that has anadjustable length. Adjustable band 340 may be a single continuous strapmember as exemplified by the upper strap 30 a in FIG. 144 or it may bemade of two or more strap members that may be secured together, e.g. bya bracket 360 as exemplified by the lower strap 30 b in FIG. 144.

For example, as exemplified in FIGS. 141-144 and 147, the first strap 30a may include an adjustable band 340 which is a single continuous strapmember that extends between a first end 341 and a second end 343 andwhich is adjustable at one or both ends 341, 343. As exemplified, theadjustable band 340 extends between the opposed (rear) ends 326 a, 326 bof the first and second side portions 322 a, 322 b and is coupled toeach of the first and second side portions 322 a, 332 b by a bracket 342a, 342 b located on each opposed end 326 a, 326 b of the side portions322 a, 322 b. For example, the first end 341 of the adjustable band 340may be fed through the bracket 342 a on the opposed end 326 a of thefirst side portion 322 a, while the second end 343 is fed through thebracket 342 b on the opposed end 326 b of the second side portion 322 b.The user may then adjust the length of the adjustable band 340.Alternately, or in addition, the adjustable band 340 may include anelastomeric material. The elastomeric adjustable band 340 may provideadditional comfort to the user by allowing for added flexibility inadjusting the length of the adjustable band 340.

Alternately, or in addition, as exemplified in FIGS. 145 and 146 thefirst strap 30 a may include third and fourth brackets 342 c and 342 d.In this embodiment, brackets 342 a, 342 b receive the band 340. Thethird and fourth brackets 342 c, 342 d may improve the adjustability ofthe securing mechanism 320 by allowing the user to adjust the adjustableband 40 at a location towards the rear of the user's head.

Accordingly, the user may adjust the mask 10 by adjusting the length ofthe first strap 30 a to improve the comfort when wearing the mask 10.The rigidity of the side portions 322 a, 322 b may allow the user toadjust the adjustable band 340 such that the side portions 322 a, 322 bare positioned to apply pressure from the first strap 30 to the mostcomfortable location for the user, which may be the rear side of thehead. Accordingly, the side portions 322 a, 322 b extend rearwardly fromthe mask and may contact the head of a user rearward of the acousticmeatus of the head and optionally reward of the temporal bone of theskull. Optionally, only the opposed end 326 a, 326 b of the sideportions 322 a, 322 b may contact the head of a user.

It will be appreciated that the shape of the side portions 322 a, 322 bmay be designed to improve the comfort of the user by reducing oressentially eliminating contact with the side portions of a head or auser. For example, as exemplified in FIGS. 141-147, the side portions322 a, 322 b may be convex. In other words, the side portions 322 a, 322b may bow away from the lateral sides 323 a, 323 b of the head of theuser such that pressure is at least reduced along the lateral sides 323a, 323 b of the user's head. In other words, the convex shape of theside portions 322 a, 322 b may allow the side portions 322 a, 322 b toengage the head of the user further rearward than they would havewithout the convex shape. For example, the side portions 322 a, 322 bmay engage the head rearward of the acoustic meatus of the head.Similarly, when a user wears glasses 370, as exemplified in FIGS.145-146, the convex shape may allow the side portions 322 a, 322 b to bepositioned laterally outwardly of temples 372 of the glasses 370. Insome embodiments, the convex shape may allow the side portions 322 a,322 b to engage the head of the user rearward of the temples 372 of theglasses 370. Engaging the head of the user rearward of the temples 372of the glasses 370 may improve the comfort of the user by allowing theglasses 370 to rest naturally on the user's head without additionalapplied pressure from the first strap 30 a.

Optionally, the side portions 322 a, 322 b may be movably attached tothe mask. Accordingly, the user may move the side portions 322 a, 322 boutwardly when putting the mask on and off. For example the mask bodyengagement ends 324 a, 324 b may be rotatably mounted to the strapattachment members 90. For example, as exemplified in FIG. 143, one ormore mask body engagement ends 324 a, 324 b may include a hook 328 andeach strap attachment 90 may include a hook receiving portion 91. Eachhook receiving portion 91 may receive one of the hooks 328 of the maskbody engagement ends 324 a, 324 b. Optionally, each of the mask bodyengagement ends 324 a, 324 b may be removably rotatably mounted to thestrap attachment members 90.

Alternately, a pivot pin may be provided on the mask of the strap.Accordingly one or more of the mask body engagement ends 324 a, 324 bmay include a pivot pin receiving portion 330 and the strap attachmentmembers 90 may include a pivot pin 93. Referring to FIG. 142, the maskbody engagement ends 334 a, 334 b of the second strap 30 b includes apivot pin receiving portion 330 that loops around the pivot pins 91 onthe mask body 12.

During use, the user may rotate the side portions 322 a, 322 b about thehook receiving portion 91 or pivot pin 93. Rotating the side portions322 a, 322 b may allow the user to vary the position of applied pressureof the first strap 30 a, thereby improving the comfort of the user. Forexample, the user may rotate the side portions 322 a, 322 b away fromtheir head to reduce pressure along the lateral sides 323 a, 323 b ofthe user's head. The user may then tighten the adjustable band 340 toensure a proper fit of the mask 10, while also relieving pressure alongthe lateral sides 323 a, 323 b of the user's head. This relief inlateral pressure along the user's head may be especially helpful whenthe user is wearing glasses 370, as exemplified in FIGS. 145 and 146. Byshifting the pressure point of the side portions 322 a, 322 b to, forexample, rearward of the temples 372 of the glasses, the user mayimprove the comfort of the mask 10.

In some embodiments, as exemplified in FIGS. 141-147, the securingmechanism 320 may include a second strap 30 b. The second strap 30 b mayfurther improve the comfort of the user by distributing the pressure ofthe securing mechanism 320 across both straps 30 a, 30 b. The secondstrap 30 b may also include a rigid portion and may be the same as firststrap 30 a. The second strap 30 b is vertically displaced from the firststrap 30 a and, as exemplified, is lower than the first strap 30 a.

As exemplified, the second strap 30 b includes a first side portion 332a and a second side portion 332 b. The first side portion 332 a extendsover a portion of the first lateral side 323 a of the head of the user,while the second side portion 332 b extends over a portion of the secondlateral side 323 b of the head of the user. As exemplified in FIGS. 142and 143, the first side portion 332 a has a mask body engagement end 334a and a rearwardly disposed opposed end 336 a, and the second sideportion 332 b has a mask body engagement end 334 b and a rearwardlydisposed opposed end 336 b. The mask body engagement ends 334 a, 334 bmay be coupled to the mask body 12 at the strap attachments 90. Asexemplified more clearly in FIG. 143, each of the first and second sideportions 332 a, 332 b of the second strap 30 b may include an adjustableband 350 for adjusting the length of the second strap 30 b. Adjustableband 350 may be the same as adjustable band 340.

In some embodiments, each adjustable band 350 a, 350 b may be anextension of the first and second side portions 332 a, 332 b,respectively, as exemplified in FIGS. 141-146. As exemplified, thesecond strap 30 b may include brackets 352 a, 352 b for adjusting thelength of the second strap 30 b, which may be any design discussed withrespect to first strap 30 a. For example, as exemplified in FIGS.141-147, the second strap 30 b may include a buckle 360 for connectingthe first portion 332 a to the second portion 332 b. As shown, thebuckle 360 may also act as a bracket for adjusting the length of thesecond strap 30 b. Accordingly, first ends 351 a, 351 b of respectiveadjustment bands 350 a, 350 b may be used to adjust the second strap 30b at the brackets 352 a, 352 b, while second ends 353 a, 353 b ofrespective adjustment bands 350 a, 350 b may be used to adjust thesecond strap 30 b at the buckle 360.

In some embodiments, each adjustable band 350 a, 350 b may be separatefrom the first and second side portions 332 a, 332 b, as exemplified inFIG. 147. As shown, the opposed ends 336 a, 336 b of the first andsecond side portions 332 a, 332 b of the second strap 30 b includebrackets 352 a, 352 b. For example, each adjustable band 350 a, 350 bmay be coupled to the respective side portion 332 a, 332 b by bracket352 a, 352 b located on each opposed end 336 a, 336 b of the sideportions 332 a, 332 b. During use, a first end 351 a of the adjustableband 350 a is fed through the bracket 352 a on the opposed end 336 a ofthe first side portion 332 a, while a second end 353 a is fed throughthe buckle 360. Similarly, a first end 351 b of the adjustable band 350b is fed through the bracket 352 b on the opposed end 336 b of thesecond side portion 332 b, while a second end 353 b is fed through thebuckle 360. The user may then adjust the length of each adjustable band350 a, 350 b at one or both of the brackets 352 a, 352 b and/or thebuckle 360. Optionally, the adjustable bands 350 a, 350 b may compriseor consist of an elastomeric material. The elastomeric adjustable bands350 a, 350 b may provide additional comfort to the user by allowing foradditional flexibility in adjusting the length of the adjustable bands350 a, 350 b.

In some embodiments, at least a portion of one of the straps 30 may betransparent. For example, in some embodiments, the first and secondportions 322 a, 322 b of the first strap 30 a may be transparent. Insome embodiments, both the first and second portions 322 a, 322 b, 332a, 332 b of the first and second straps 30 a, 30 b may be transparent.

It will be appreciated that, while shown with a filter mask 10, thesecuring mechanism 320 may be used to secure any headwear to the head ofa user. For example, the securing mechanism 320 may be used withlaboratory goggles, ski goggles, scuba masks, swimming goggles, safetygoggles, sports masks, welding masks, and the like.

Eye Shields

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, a shield may be provided inthe volume 28 between the face plate and the face of a user to inhibitor prevent air flowing over the eyes of a user. An advantage of thisdesign is that air may be diverted from flowing in front of the eyes ofa user, which may tend to dry the eyes of the user.

As exemplified in FIGS. 38-41, eye shields 168 may be positioned so asto inhibit or prevent air travelling downwardly across a person's eyesor upwardly across a person's eyes.

Anti-Microbial Agent

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, any or all portions of thefilter mask 10 may be provided with a layer of an antimicrobial agent,such as Indian tin oxide, copper, silver, zinc or any combinationthereof. Accordingly, the inner surface of the face plate 20 and any orall portions of the air flow path may be coated with, e.g., Indian tinoxide copper, silver, zinc or any combination thereof.

Optionally, the foam filter media 118 may be coated with any such agent(e.g., copper coated reticulated polyurethane foam). Materials, such ascopper, produce ions that destroy a virus. Silver will also destroy avirus but requires the presence of moisture. Therefore, if silver isused, a moisture source (e.g., atomized water) to provide moisture tothe foam filter media 118 may optionally be provided.

A metal antimicrobial agent may be vapor deposited or applied using aplasma spray to any portion of filter mask 10, including one or morelayers of the filter media. Alternately, or in addition, nanoparticlesof a metal anti-microbial agent (e.g., nanoparticles of copper, silver,zinc or a mixture thereof) may be applied to foam filter media 118.

Optionally, the metal anti-microbial agent may be applied to an opencell foam to reduce the size of the pores so as to provide an open cellfoam having a desired reduced pore size. An advantage of this design isthat a more porous open cell foam may be converted to a finer filtermaterial while adding an anti-microbial activity to the foam. Forexample, an open cell foam such as polypropylene, having 0.2-100 or0.5-50 or 3-25 micron pores prior to application of the anti-microbialagent may be converted to an open cell foam having, e.g., 0.05-0.1micron pores after application of the anti-microbial agent

Ear Covers

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, filter mask 10 may beprovided with ear flaps 86 that overlie the ears to inhibit or preventdroplets from entering the ears of a person wearing the filter mask 10(see FIG. 1). The ear flaps 86 may merely overlie the ears of the personor they may seat on the head and surround the ears (e.g., likeheadphones) to enclose the ears.

Cooling

In accordance with this aspect, which may be used by itself or incombination with one or more other aspects, the incoming air may becooled by exposing the incoming air to water. For example, water may besprayed, e.g., by an atomizer, to the air being inhaled at a locationupstream of the biological filter material 116 and optionally upstreamof the more porous filter media (the foam/felt filter media 118, 120).Alternately, or in addition, water may be provided to the more porousfilter media (the foam/felt filter media 118, 120). For example, asexemplified in FIG. 11, an atomizer 142 may be provided with a volume tostore water. An energy storage member 144 (e.g., a battery or acapacitor) may power the atomizer 142. Atomized water may travel throughdischarge passage 140 (optionally with the assist of a fan) to provideatomized water to the air being inhaled. It will be appreciated that, inan alternate embodiment, discharge passage may be provided internal offoam filter media 118.

While the above description describes features of example embodiments,it will be appreciated that some features and/or functions of thedescribed embodiments are susceptible to modification without departingfrom the spirit and principles of operation of the describedembodiments. For example, the various characteristics which aredescribed by means of the represented embodiments or examples may beselectively combined with each other. Accordingly, what has beendescribed above is intended to be illustrative of the claimed conceptand non-limiting. It will be understood by persons skilled in the artthat other variants and modifications may be made without departing fromthe scope of the invention as defined in the claims appended hereto. Thescope of the claims should not be limited by the preferred embodimentsand examples, but should be given the broadest interpretation consistentwith the description as a whole.

1. A mask comprising: (a) a mask body having a front and first andsecond laterally opposed sides, each laterally opposed side having astrap attachment member; and, (b) a first strap for extending around ahead of a user, the first strap comprising a first side portion which,when worn by the user, extends over a portion of a first lateral side ofthe head of the user and a second side portion which, when worn by theuser, extends over a portion of a second lateral side of the head of theuser, wherein the first side portion and the second side portion arerigid.
 2. The mask of claim 1 wherein the first side portion and thesecond side portion are convex.
 3. The mask of claim 2 wherein, when theuser is wearing glasses, the first side portion and the second sideportion are positioned laterally outwardly of temples of the glasses. 4.The mask of claim 3 wherein each of the first side portion and thesecond side portion engage the head of the user rearward of the templesof the glasses.
 5. The mask of claim 1 wherein each of the first sideportion and the second side portion engage the head of the user rearwardof the external acoustic meatus of the head.
 6. The mask of claim 1wherein the first side portion and the second side portion are made froma rigid plastic.
 7. The mask of claim 6 wherein the rigid plastic isABS, HDPE, nylon or polycarbonate.
 8. The mask of claim 1 wherein eachof the first side portion and the second side portion have a mask bodyengagement end and a rearwardly disposed opposed end and the first strapfurther comprises an adjustable band which extends between the opposedends of the first side portion and the second side portion.
 9. The maskof claim 8 wherein the adjustable band comprises an elastomericmaterial.
 10. The mask of claim 8 wherein the adjustable band has anadjustable length.
 11. The mask of claim 1 wherein each of the firstside portion and the second side portion have a mask body engagement endand a rearwardly disposed opposed end and the mask body engagement endsare rotatably mounted to the strap attachment members.
 12. The mask ofclaim 11 wherein each of the mask body engagement ends are removablyrotatably mounted to the strap attachment members.
 13. The mask of claim11 wherein each of the mask body engagement ends comprises a hook andeach of the strap attachment members comprises a hook receiving portionwhereby each hook receiving portion receives one of the mask bodyengagement ends.
 14. The mask of claim 11 wherein each of the mask bodyengagement ends comprises a pivot pin receiving portion and each of thestrap attachment members comprises a pivot pin.
 15. The mask of claim 1further comprising a second strap.
 16. The mask of claim 15 wherein thesecond strap comprises a first side portion which, when worn by theuser, extends over a portion of the first lateral side of the head ofthe user and a second side portion which, when worn by the user, extendsover a portion of the second lateral side of the head of the user,wherein the first side portion and the second side portion of the secondstrap are rigid.
 17. The mask of claim 1 wherein each of the first sideportion and the second side portion are transparent.
 18. The mask ofclaim 16 wherein each of the first side portion and the second sideportion of each of the first strap and the second strap are transparent.